Factory Workshop Manual
Make
Ford
Model
Explorer Sport 2wd
Engine and year
V6-245 4.0L SOHC VIN K SFI (2001)
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This manual was submitted by
Anonymous
Date
1st January 2018
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104,
( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102
P0100 - P0104: Testing and Inspection P0102
For diagnosis of code P0102 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104,
( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 9
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104,
( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 10
P0100 - P0104: Testing and Inspection P0103
For diagnosis of code P0103 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104,
( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 11
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106
P0105 - P0109: Testing and Inspection P0106
For diagnosis of code P0106 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 16
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 17
P0105 - P0109: Testing and Inspection P0107
For diagnosis of code P0107 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 18
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 19
P0105 - P0109: Testing and Inspection P0108
For diagnosis of code P0108 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 20
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 21
P0105 - P0109: Testing and Inspection P0109
For diagnosis of code P0109 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 22
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114,
( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112
P0110 - P0114: Testing and Inspection P0112
For diagnosis of code P0112 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114,
( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 27
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114,
( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 28
P0110 - P0114: Testing and Inspection P0113
For diagnosis of code P0113 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114,
( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 29
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116
P0115 - P0119: Testing and Inspection P0116
For diagnosis of code P0116 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 34
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 35
P0115 - P0119: Testing and Inspection P0117
For diagnosis of code P0117 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 36
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 37
P0115 - P0119: Testing and Inspection P0118
For diagnosis of code P0118 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 38
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121
P0120 - P0124: Testing and Inspection P0121
For diagnosis of code P0121 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 43
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 44
P0120 - P0124: Testing and Inspection P0122
For diagnosis of code P0122 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 45
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 46
P0120 - P0124: Testing and Inspection P0123
For diagnosis of code P0123 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 47
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129,
( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125
P0125 - P0129: Testing and Inspection P0125
For diagnosis of code P0125 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129,
( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 52
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129,
( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 53
P0125 - P0129: Testing and Inspection P0127
For diagnosis of code P0127 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129,
( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 54
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134,
( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131
P0130 - P0134: Testing and Inspection P0131
For diagnosis of code P0131 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134,
( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 59
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134,
( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 60
P0130 - P0134: Testing and Inspection P0133
For diagnosis of code P0133 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134,
( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 61
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139,
( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135
P0135 - P0139: Testing and Inspection P0135
For diagnosis of code P0135 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139,
( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 66
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139,
( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 67
P0135 - P0139: Testing and Inspection P0136
For diagnosis of code P0136 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139,
( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 68
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144,
( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis
P0140 - P0144: Testing and Inspection
For diagnosis of code P0141 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144,
( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > Page 72
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149,
( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis
P0145 - P0149: Testing and Inspection
For diagnosis of code P0148 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149,
( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > Page 76
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154,
( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151
P0150 - P0154: Testing and Inspection P0151
For diagnosis of code P0151 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154,
( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 81
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154,
( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 82
P0150 - P0154: Testing and Inspection P0153
For diagnosis of code P0153 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154,
( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 83
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159,
( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155
P0155 - P0159: Testing and Inspection P0155
For diagnosis of code P0155 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159,
( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 88
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159,
( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 89
P0155 - P0159: Testing and Inspection P0156
For diagnosis of code P0156 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159,
( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 90
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164,
( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis
P0160 - P0164: Testing and Inspection
For diagnosis of code P0161 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164,
( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis > Page 94
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171
P0170 - P0174: Testing and Inspection P0171
For diagnosis of code P0171 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 99
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 100
P0170 - P0174: Testing and Inspection P0172
For diagnosis of code P0172 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 101
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 102
P0170 - P0174: Testing and Inspection P0174
For diagnosis of code P0174 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 103
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179,
( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175
P0175 - P0179: Testing and Inspection P0175
For diagnosis of code P0175 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179,
( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 108
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179,
( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 109
P0175 - P0179: Testing and Inspection P0176
For diagnosis of code P0176 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179,
( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 110
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180
P0180 - P0184: Testing and Inspection P0180
For diagnosis of code P0180 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 115
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 116
P0180 - P0184: Testing and Inspection P0181
For diagnosis of code P0181 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 117
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 118
P0180 - P0184: Testing and Inspection P0182
For diagnosis of code P0182 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 119
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 120
P0180 - P0184: Testing and Inspection P0183
For diagnosis of code P0183 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 121
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190
P0190 - P0194: Testing and Inspection P0190
For diagnosis of code P0190 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 126
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 127
P0190 - P0194: Testing and Inspection P0191
For diagnosis of code P0191 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 128
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 129
P0190 - P0194: Testing and Inspection P0192
For diagnosis of code P0192 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 130
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 131
P0190 - P0194: Testing and Inspection P0193
For diagnosis of code P0193 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 132
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201
P0200 - P0204: Testing and Inspection P0201
For diagnosis of code P0201 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 138
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 139
P0200 - P0204: Testing and Inspection P0202
For diagnosis of code P0202 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 140
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 141
P0200 - P0204: Testing and Inspection P0203
For diagnosis of code P0203 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 142
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 143
P0200 - P0204: Testing and Inspection P0204
For diagnosis of code P0204 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 144
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205
P0205 - P0209: Testing and Inspection P0205
For diagnosis of code P0205 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 149
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 150
P0205 - P0209: Testing and Inspection P0206
For diagnosis of code P0206 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 151
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 152
P0205 - P0209: Testing and Inspection P0207
For diagnosis of code P0207 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 153
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 154
P0205 - P0209: Testing and Inspection P0208
For diagnosis of code P0208 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 155
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 156
P0205 - P0209: Testing and Inspection P0209
For diagnosis of code P0209 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 157
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210
P0210 - P0214: Testing and Inspection P0210
For diagnosis of code P0210 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 162
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 163
P0210 - P0214: Testing and Inspection P0211
For diagnosis of code P0211 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 164
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 165
P0210 - P0214: Testing and Inspection P0212
For diagnosis of code P0212 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 166
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219,
( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis
P0215 - P0219: Testing and Inspection
For diagnosis of code P0217 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219,
( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > Page 170
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230
P0230 - P0234: Testing and Inspection P0230
For diagnosis of code P0230 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 175
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 176
P0230 - P0234: Testing and Inspection P0231
For diagnosis of code P0231 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 177
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 178
P0230 - P0234: Testing and Inspection P0232
For diagnosis of code P0232 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 179
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 180
P0230 - P0234: Testing and Inspection P0234
For diagnosis of code P0234 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 181
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244,
( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis
P0240 - P0244: Testing and Inspection
For diagnosis of code P0243 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244,
( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis > Page 185
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299,
( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis
P0295 - P0299: Testing and Inspection
For diagnosis of code P0298 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299,
( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > Page 189
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300
P0300 - P0304: Testing and Inspection P0300
For diagnosis of code P0300 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 195
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 196
P0300 - P0304: Testing and Inspection P0301
For diagnosis of code P0301 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 197
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 198
P0300 - P0304: Testing and Inspection P0302
For diagnosis of code P0302 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 199
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 200
P0300 - P0304: Testing and Inspection P0303
For diagnosis of code P0303 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 201
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 202
P0300 - P0304: Testing and Inspection P0304
For diagnosis of code P0304 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 203
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305
P0305 - P0309: Testing and Inspection P0305
For diagnosis of code P0305 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 208
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 209
P0305 - P0309: Testing and Inspection P0306
For diagnosis of code P0306 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 210
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 211
P0305 - P0309: Testing and Inspection P0307
For diagnosis of code P0307 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 212
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 213
P0305 - P0309: Testing and Inspection P0308
For diagnosis of code P0308 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 214
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 215
P0305 - P0309: Testing and Inspection P0309
For diagnosis of code P0309 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 216
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314,
( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis
P0310 - P0314: Testing and Inspection
For diagnosis of code P0310 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314,
( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis > Page 220
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324,
( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis
P0320 - P0324: Testing and Inspection
For diagnosis of code P0320 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324,
( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis > Page 224
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329,
( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325
P0325 - P0329: Testing and Inspection P0325
For diagnosis of code P0325 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329,
( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 229
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329,
( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 230
P0325 - P0329: Testing and Inspection P0326
For diagnosis of code P0326 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329,
( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 231
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334,
( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330
P0330 - P0334: Testing and Inspection P0330
For diagnosis of code P0330 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334,
( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 236
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334,
( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 237
P0330 - P0334: Testing and Inspection P0331
For diagnosis of code P0331 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334,
( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 238
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344,
( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis
P0340 - P0344: Testing and Inspection
For diagnosis of code P0340 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344,
( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > Page 242
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350
P0350 - P0354: Testing and Inspection P0350
For diagnosis of code P0350 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 247
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 248
P0350 - P0354: Testing and Inspection P0351
For diagnosis of code P0351 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 249
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 250
P0350 - P0354: Testing and Inspection P0352
For diagnosis of code P0352 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 251
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 252
P0350 - P0354: Testing and Inspection P0353
For diagnosis of code P0353 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 253
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 254
P0350 - P0354: Testing and Inspection P0354
For diagnosis of code P0354 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 255
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355
P0355 - P0359: Testing and Inspection P0355
For diagnosis of code P0355 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 260
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 261
P0355 - P0359: Testing and Inspection P0356
For diagnosis of code P0356 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 262
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 263
P0355 - P0359: Testing and Inspection P0357
For diagnosis of code P0357 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 264
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 265
P0355 - P0359: Testing and Inspection P0358
For diagnosis of code P0358 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 266
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 267
P0355 - P0359: Testing and Inspection P0359
For diagnosis of code P0359 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 268
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364,
( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis
P0360 - P0364: Testing and Inspection
For diagnosis of code P0360 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364,
( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis > Page 272
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400
P0400 - P0404: Testing and Inspection P0400
For diagnosis of code P0400 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 278
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 279
P0400 - P0404: Testing and Inspection P0401
For diagnosis of code P0401 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 280
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 281
P0400 - P0404: Testing and Inspection P0402
For diagnosis of code P0402 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 282
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 283
P0400 - P0404: Testing and Inspection P0403
For diagnosis of code P0403 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 284
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414,
( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411
P0410 - P0414: Testing and Inspection P0411
For diagnosis of code P0411 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414,
( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 289
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414,
( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 290
P0410 - P0414: Testing and Inspection P0412
For diagnosis of code P0412 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414,
( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 291
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424,
( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis
P0420 - P0424: Testing and Inspection
For diagnosis of code P0420 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424,
( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis > Page 295
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434,
( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis
P0430 - P0434: Testing and Inspection
For diagnosis of code P0430 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434,
( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis > Page 299
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444,
( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442
P0440 - P0444: Testing and Inspection P0442
For diagnosis of code P0442 refer to chart
DTC Index P0442 - P1450
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information , See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444,
( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 304
P0440 - P0444: Testing and Inspection P0443
For diagnosis of code P0443 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444,
( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 305
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451
P0450 - P0454: Testing and Inspection P0451
For diagnosis of code P0451 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 310
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 311
P0450 - P0454: Testing and Inspection P0452
For diagnosis of code P0452 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 312
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 313
P0450 - P0454: Testing and Inspection P0453
For diagnosis of code P0453 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 314
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459,
( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455
P0455 - P0459: Testing and Inspection P0455
For diagnosis of code P0455 refer to chart
DTC Index P0442 - P1450
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information , See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459,
( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 319
P0455 - P0459: Testing and Inspection P0456
For diagnosis of code P0456 refer to chart
DTC Index P0442 - P1450
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information , See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459,
( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 320
P0455 - P0459: Testing and Inspection P0457
For diagnosis of code P0457 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459,
( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 321
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464,
( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460
P0460 - P0464: Testing and Inspection P0460
For diagnosis of code P0460 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464,
( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 326
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464,
( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 327
P0460 - P0464: Testing and Inspection P0461
For diagnosis of code P0461 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464,
( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 328
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500
P0500 - P0504: Testing and Inspection P0500
For diagnosis of P0500 refer to system experiencing problems.
Engine Control System or Transmission Control System
P0443 - P071x
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 334
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control System diagnostic information, See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Wiper and Washer Systems
DTC Index P0500 - B1432
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Wiper and Washer system diagnostic information, See: Wiper and Washer
Systems/Testing and Inspection
Transfer Case
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 335
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 336
P0500 - P0504: Testing and Inspection P0501
For diagnosis of code P0501 refer to chart
P0443 - P071x
NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform
complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 337
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 338
P0500 - P0504: Testing and Inspection P0503
For diagnosis of code P0503 refer to chart
P0443 - P071x
NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform
complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 339
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509,
( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis
P0505 - P0509: Testing and Inspection
For diagnosis of code P0505 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509,
( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > Page 343
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554,
( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552
P0550 - P0554: Testing and Inspection P0552
For diagnosis of code P0552 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554,
( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 348
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554,
( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 349
P0550 - P0554: Testing and Inspection P0553
For diagnosis of code P0553 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554,
( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 350
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602
P0600 - P0604: Testing and Inspection P0602
For diagnosis of code P0602 refer to chart
P0443 - P071x
NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to VID Block Procedure.
See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 356
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 357
P0600 - P0604: Testing and Inspection P0603
For diagnosis of code P0603 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 358
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609,
( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis
P0605 - P0609: Testing and Inspection
For diagnosis of code P0605 refer to chart
P0443 - P071x
NOTE 14: Be sure to check for aftermarket performance products before replacing PCM. If
replacement is necessary refer to Flash Electrically Erasable Programmable Read Only Memory
(EEPROM), See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609,
( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > Page 362
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704,
( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703
P0700 - P0704: Testing and Inspection P0703
For diagnosis of code P0703 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704,
( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 368
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704,
( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 369
P0700 - P0704: Testing and Inspection P0704
For diagnosis of code P0704 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704,
( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 370
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709,
( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705
P0705 - P0709: Testing and Inspection P0705
For diagnosis of code P0705 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709,
( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 375
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709,
( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 376
P0705 - P0709: Testing and Inspection P0708
For diagnosis of code P0708 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709,
( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 377
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714,
( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712
P0710 - P0714: Testing and Inspection P0712
For diagnosis of code P0712 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714,
( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 382
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714,
( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 383
P0710 - P0714: Testing and Inspection P0713
For diagnosis of code P0713 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714,
( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 384
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719,
( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis
P0715 - P0719: Testing and Inspection
For diagnosis of code P0715 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission
P0720 - P0724: Testing and Inspection Manual Transmission
For diagnosis of code P072x refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission >
Page 392
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Note: "x" = any number 0 thru 9
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission >
Page 393
P0720 - P0724: Testing and Inspection Automatic Transmission
P0720
For diagnosis of code P0720 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission >
Page 394
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
P0721
For diagnosis of code P0721 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729,
( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis
P0725 - P0729: Testing and Inspection
For diagnosis of code P072x refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729,
( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis > Page 398
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Note: "x" = any number 0 thru 9
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731
P0730 - P0734: Testing and Inspection P0731
For diagnosis of code P0731 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 403
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 404
P0730 - P0734: Testing and Inspection P0732
For diagnosis of code P0732 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 405
Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 406
P0730 - P0734: Testing and Inspection P0733
For diagnosis of code P0733 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 407
Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 408
P0730 - P0734: Testing and Inspection P0734
For diagnosis of code P0734 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 409
Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739,
( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis
P0735 - P0739: Testing and Inspection
For diagnosis of code P0735 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739,
( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis > Page 413
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744,
( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741
P0740 - P0744: Testing and Inspection P0741
For diagnosis of code P0741 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744,
( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 418
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744,
( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 419
P0740 - P0744: Testing and Inspection P0743
For diagnosis of code P0743 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744,
( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 420
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754,
( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis
P0750 - P0754: Testing and Inspection
For diagnosis of code P0750 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759,
( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis
P0755 - P0759: Testing and Inspection
For diagnosis of code P0755 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764,
( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis
P0760 - P0764: Testing and Inspection
For diagnosis of code P0760 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764,
( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis > Page 430
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769,
( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis
P0765 - P0769: Testing and Inspection
For diagnosis of code P0765 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769,
( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis > Page 434
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791
P0790 - P0794: Testing and Inspection P0791
For diagnosis of code P0791 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 439
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 440
P0790 - P0794: Testing and Inspection P0794
For diagnosis of code P0794 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 441
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814,
( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis
P0810 - P0814: Testing and Inspection
For diagnosis of code P0812 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814,
( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis > Page 446
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004,
( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000
P1000 - P1004: Testing and Inspection P1000
For diagnosis of code P1000 refer to chart
P072x - P1138
NOTE 1: DTC P1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and
continue as directed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004,
( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 452
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004,
( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 453
P1000 - P1004: Testing and Inspection P1001
For diagnosis of code P1001 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004,
( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 454
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104,
( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100
P1100 - P1104: Testing and Inspection P1100
For diagnosis of code P1100 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104,
( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 460
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104,
( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 461
P1100 - P1104: Testing and Inspection P1101
For diagnosis of code P1101 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104,
( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 462
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112
P1110 - P1114: Testing and Inspection P1112
For diagnosis of code P1112 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 467
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 468
P1110 - P1114: Testing and Inspection P1114
For diagnosis of code P1114 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 469
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115
P1115 - P1119: Testing and Inspection P1115
For diagnosis of code P1115 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 474
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 475
P1115 - P1119: Testing and Inspection P1116
For diagnosis of code P1116 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 476
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 477
P1115 - P1119: Testing and Inspection P1117
For diagnosis of code P1117 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 478
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120
P1120 - P1124: Testing and Inspection P1120
For diagnosis of code P1120 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 483
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 484
P1120 - P1124: Testing and Inspection P1121
For diagnosis of code P1121 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 485
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 486
P1120 - P1124: Testing and Inspection P1124
For diagnosis of code P1124 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 487
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125
P1125 - P1129: Testing and Inspection P1125
For diagnosis of code P1125 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 492
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 493
P1125 - P1129: Testing and Inspection P1127
For diagnosis of code P1127 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 494
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 495
P1125 - P1129: Testing and Inspection P1128
For diagnosis of code P1128 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 496
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 497
P1125 - P1129: Testing and Inspection P1129
For diagnosis of code P1129 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 498
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130
P1130 - P1134: Testing and Inspection P1130
For diagnosis of code P1130 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 503
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 504
P1130 - P1134: Testing and Inspection P1131
For diagnosis of code P1131 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 505
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 506
P1130 - P1134: Testing and Inspection P1132
For diagnosis of code P1132 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 507
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139,
( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137
P1135 - P1139: Testing and Inspection P1137
For diagnosis of code P1137 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139,
( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 512
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139,
( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 513
P1135 - P1139: Testing and Inspection P1138
For diagnosis of code P1138 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139,
( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 514
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150
P1150 - P1154: Testing and Inspection P1150
For diagnosis of code P1150 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 519
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 520
P1150 - P1154: Testing and Inspection P1151
For diagnosis of code P1151 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 521
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 522
P1150 - P1154: Testing and Inspection P1152
For diagnosis of code P1152 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 523
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159,
( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157
P1155 - P1159: Testing and Inspection P1157
For diagnosis of code P1157 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159,
( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 528
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159,
( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 529
P1155 - P1159: Testing and Inspection P1158
For diagnosis of code P1158 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159,
( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 530
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169,
( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168
P1165 - P1169: Testing and Inspection P1168
For diagnosis of code P1168 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169,
( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 535
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169,
( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 536
P1165 - P1169: Testing and Inspection P1169
For diagnosis of code P1169 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169,
( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 537
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180
P1180 - P1184: Testing and Inspection P1180
For diagnosis of code P1180 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 542
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 543
P1180 - P1184: Testing and Inspection P1181
For diagnosis of code P1181 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 544
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 545
P1180 - P1184: Testing and Inspection P1183
For diagnosis of code P1183 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 546
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 547
P1180 - P1184: Testing and Inspection P1184
For diagnosis of code P1184 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 548
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229,
( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis
P1225 - P1229: Testing and Inspection
For diagnosis of code P1229 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229,
( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis > Page 553
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232
P1230 - P1234: Testing and Inspection P1232
For diagnosis of code P1232 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 558
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 559
P1230 - P1234: Testing and Inspection P1233
For diagnosis of code P1233 refer to chart
P1150 - P1401
NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 560
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 561
P1230 - P1234: Testing and Inspection P1234
For diagnosis of code P1234 refer to chart
P1150 - P1401
NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 562
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235
P1235 - P1239: Testing and Inspection P1235
For diagnosis of code P1235 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 567
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 568
P1235 - P1239: Testing and Inspection P1236
For diagnosis of code P1236 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 569
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 570
P1235 - P1239: Testing and Inspection P1237
For diagnosis of code P1237 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 571
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 572
P1235 - P1239: Testing and Inspection P1238
For diagnosis of code P1238 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 573
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244,
( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis
P1240 - P1244: Testing and Inspection
For diagnosis of code P1244 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244,
( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis > Page 577
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249,
( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245
P1245 - P1249: Testing and Inspection P1245
For diagnosis of code P1245 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249,
( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 582
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249,
( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 583
P1245 - P1249: Testing and Inspection P1246
For diagnosis of code P1246 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249,
( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 584
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis
P1260 - P1264: Testing and Inspection
For diagnosis of code P1260 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > Page 588
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis
P1270 - P1274: Testing and Inspection
For diagnosis of code P1270 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > Page 592
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285
P1285 - P1289: Testing and Inspection P1285
For diagnosis of code P1285 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 597
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 598
P1285 - P1289: Testing and Inspection P1288
For diagnosis of code P1288 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 599
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 600
P1285 - P1289: Testing and Inspection P1289
For diagnosis of code P1289 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 601
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294,
( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis
P1290 - P1294: Testing and Inspection
For diagnosis of code P1290 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294,
( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis > Page 605
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299,
( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis
P1295 - P1299: Testing and Inspection
For diagnosis of code P1299 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299,
( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis > Page 609
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309,
( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis
P1305 - P1309: Testing and Inspection
For diagnosis of code P1309 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309,
( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis > Page 614
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380
P1380 - P1384: Testing and Inspection P1380
For diagnosis of code P1380 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 619
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 620
P1380 - P1384: Testing and Inspection P1381
For diagnosis of code P1381 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 621
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 622
P1380 - P1384: Testing and Inspection P1383
For diagnosis of code P1383 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 623
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404,
( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400
P1400 - P1404: Testing and Inspection P1400
For diagnosis of code P1400 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404,
( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 629
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404,
( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 630
P1400 - P1404: Testing and Inspection P1401
For diagnosis of code P1401 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404,
( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 631
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405
P1405 - P1409: Testing and Inspection P1405
For diagnosis of code P1405 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 636
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 637
P1405 - P1409: Testing and Inspection P1406
For diagnosis of code P1406 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 638
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 639
P1405 - P1409: Testing and Inspection P1408
For diagnosis of code P1408 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 640
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 641
P1405 - P1409: Testing and Inspection P1409
For diagnosis of code P1409 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 642
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414,
( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413
P1410 - P1414: Testing and Inspection P1413
For diagnosis of code P1413 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414,
( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 647
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414,
( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 648
P1410 - P1414: Testing and Inspection P1414
For diagnosis of code P1414 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414,
( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 649
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434,
( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis
P1430 - P1434: Testing and Inspection
For diagnosis of code P1432 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434,
( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis > Page 653
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444,
( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis
P1440 - P1444: Testing and Inspection
For diagnosis of code P1443 refer to chart
DTC Index P0442 - P1450
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information , See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454,
( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450
P1450 - P1454: Testing and Inspection P1450
For diagnosis of code P1450 refer to the system experiencing the problem.
Computers and Control Systems
P1405 - P1517
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454,
( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 661
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Evaporative Emissions System
DTC Index P0442 - P1450
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information, See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454,
( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 662
P1450 - P1454: Testing and Inspection P1451
For diagnosis of code P1451 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454,
( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 663
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460
P1460 - P1464: Testing and Inspection P1460
For diagnosis of code P1460 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 668
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 669
P1460 - P1464: Testing and Inspection P1461
For diagnosis of code P1461 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 670
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 671
P1460 - P1464: Testing and Inspection P1462
For diagnosis of code P1462 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 672
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 673
P1460 - P1464: Testing and Inspection P1463
For diagnosis of code P1463 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 674
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 675
P1460 - P1464: Testing and Inspection P1464
For diagnosis of code P1464 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 676
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469,
( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis
P1465 - P1469: Testing and Inspection
For diagnosis of code P1469 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469,
( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis > Page 680
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474,
( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis
P1470 - P1474: Testing and Inspection
For diagnosis of code P1474 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474,
( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis > Page 684
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477
P1475 - P1479: Testing and Inspection P1477
For diagnosis of code P1477 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 689
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 690
P1475 - P1479: Testing and Inspection P1479
For diagnosis of code P1479 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 691
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500
P1500 - P1504: Testing and Inspection P1500
For diagnosis of code P1500 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 697
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 698
P1500 - P1504: Testing and Inspection P1501
For diagnosis of code P1501 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 699
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 700
P1500 - P1504: Testing and Inspection P1502
For diagnosis of code P1502 refer to chart
P1405 - P1517
NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform
complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 701
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 702
P1500 - P1504: Testing and Inspection P1504
For diagnosis of code P1504 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 703
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509,
( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506
P1505 - P1509: Testing and Inspection P1506
For diagnosis of code P1506 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509,
( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 708
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509,
( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 709
P1505 - P1509: Testing and Inspection P1507
For diagnosis of code P1507 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509,
( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 710
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516
P1515 - P1519: Testing and Inspection P1516
For diagnosis of code P1516 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 715
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 716
P1515 - P1519: Testing and Inspection P1517
For diagnosis of code P1517 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 717
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 718
P1515 - P1519: Testing and Inspection P1518
For diagnosis of code P1518 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 719
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 720
P1515 - P1519: Testing and Inspection P1519
For diagnosis of code P1519 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 721
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524,
( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis
P1520 - P1524: Testing and Inspection
For diagnosis of code P1520 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524,
( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis > Page 725
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549,
( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis
P1545 - P1549: Testing and Inspection
For diagnosis of code P1549 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549,
( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis > Page 729
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554,
( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis
P1550 - P1554: Testing and Inspection
For diagnosis of code P1550 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554,
( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis > Page 733
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574,
( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis
P1570 - P1574: Testing and Inspection
For diagnosis of code P1572 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574,
( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis > Page 737
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609,
( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis
P1605 - P1609: Testing and Inspection
For diagnosis of code P1605 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609,
( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis > Page 742
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634,
( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis
P1630 - P1634: Testing and Inspection
For diagnosis of code P1633 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634,
( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis > Page 746
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635
P1635 - P1639: Testing and Inspection P1635
For diagnosis of code P1635 refer to chart
P1518 - P1781
NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block
procedure, See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 751
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 752
P1635 - P1639: Testing and Inspection P1636
For diagnosis of code P1636 refer to chart
P1518 - P1781
NOTE 18: DTC P1636 indicates the PCM has lost communication with the Inductive Signature
Chip. Replace PCM. If replacement is necessary refer to Flash Electically Erasable Programmable
Read Only Memory (EEPROM), See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Programming and Relearning
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 753
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 754
P1635 - P1639: Testing and Inspection P1639
For diagnosis of code P1639 refer to chart
P1518 - P1781
NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block
procedure, See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 755
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644,
( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis
P1640 - P1644: Testing and Inspection
For diagnosis of code P1641 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644,
( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > Page 759
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654,
( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650
P1650 - P1654: Testing and Inspection P1650
For diagnosis of code P1650 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654,
( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 764
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654,
( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 765
P1650 - P1654: Testing and Inspection P1651
For diagnosis of code P1651 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654,
( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 766
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702
P1700 - P1704: Testing and Inspection P1702
For diagnosis of code P1702 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 772
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 773
P1700 - P1704: Testing and Inspection P1703
For diagnosis of code P1703 refer to charts
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 774
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 775
P1700 - P1704: Testing and Inspection P1704
For diagnosis of code P1704 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 776
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705
P1705 - P1709: Testing and Inspection P1705
Manual Transmission
For diagnosis of code P1705 refer to chart
P1518 - P1781
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Automatic Transmission
For diagnosis of code P1705 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 782
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 783
P1705 - P1709: Testing and Inspection P1709
For diagnosis of code P1709 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 784
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711
P1710 - P1714: Testing and Inspection P1711
For diagnosis of code P1711 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 789
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 790
P1710 - P1714: Testing and Inspection P1713
For diagnosis of code P1713 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 791
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 792
P1710 - P1714: Testing and Inspection P1714
For diagnosis of code P1714 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 793
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715
P1715 - P1719: Testing and Inspection P1715
For diagnosis of code P1715 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 798
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 799
P1715 - P1719: Testing and Inspection P1716
For diagnosis of code P1716 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 800
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 801
P1715 - P1719: Testing and Inspection P1717
For diagnosis of code P1717 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 802
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 803
P1715 - P1719: Testing and Inspection P1718
For diagnosis of code P1718 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 804
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729,
( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis
P1725 - P1729: Testing and Inspection
For diagnosis of code P1729 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729,
( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > Page 808
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744,
( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis
P1740 - P1744: Testing and Inspection
For diagnosis of code P1740 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744,
( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > Page 812
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749,
( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746
P1745 - P1749: Testing and Inspection P1746
For diagnosis of code P1746 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749,
( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 817
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749,
( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 818
P1745 - P1749: Testing and Inspection P1747
For diagnosis of code P1747 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749,
( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 819
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780
P1780 - P1784: Testing and Inspection P1780
For diagnosis of code P1780 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 824
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 825
P1780 - P1784: Testing and Inspection P1781
For diagnosis of code P1781 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 826
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 827
P1780 - P1784: Testing and Inspection P1783
For diagnosis of code P1783 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 828
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904,
( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission
P1900 - P1904: Testing and Inspection Manual Transmission
For diagnosis of code P1900 refer to charts
P1783 - P1900
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904,
( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission >
Page 834
-
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904,
( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission >
Page 835
P1900 - P1904: Testing and Inspection Automatic Transmission
For diagnosis of code P1900 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security
Module
Multifunction Electronic Control Modules: Locations Central Security Module
Vehicles Built AFTER 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security
Module > Page 845
Multifunction Electronic Control Modules: Locations Generic Electronic Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security
Module > Page 846
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security
Module > Page 847
Multifunction Electronic Control Modules: Locations Remote Anti-Theft Personality Module
Vehicles Built BEFORE 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions
Multifunction Electronic Control Modules: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 850
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 851
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 852
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 853
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 854
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 855
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 856
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 857
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 858
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 859
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 860
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 861
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 862
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 863
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 864
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 865
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 866
Multifunction Electronic Control Modules: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 867
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 868
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 869
Multifunction Electronic Control Modules: Connector Views
Central Security Module
Vehicles Built AFTER 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 870
Generic Electronic Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 871
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 872
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 873
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 874
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 875
Remote Anti-Theft Personality Module
Vehicles Built BEFORE 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 876
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 877
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 878
Multifunction Electronic Control Modules: Electrical Diagrams
Diagram 419-10-00-1
Diagram 419-10-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 879
Diagram 419-10-00-3
Diagram 419-10-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 880
Multifunction Electronic Control Modules: Service Precautions
CAUTION:
^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module
configuration information to the diagnostic tool. This information needs to be downloaded into, the
new module once installed.
^ Once the new module is installed, it is necessary to download module configuration information
from the appropriate diagnostic tool into the new module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation >
System Description
Multifunction Electronic Control Modules: Description and Operation System Description
Module Controlled Functions
NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module
configuration information to a diagnostic tool. This information needs to be downloaded into the
new module once installed.
The multifunction module consists of the following:
^ Generic Electronic Module (GEM)
^ Remote Anti-theft Personality (RAP) module (vehicles built before 7/24/2000)
^ central security module (vehicles built after 7/24/2000)
The GEM controls the following features: ^
front wiper and washer
^ rear wiper and washer
^ warning chime
^ battery saver
^ illuminated entry and interior lighting
^ driver one-touch down power window (optional)
^ battery saver relay
^ door ajar warning indicator lamp
^ safety belt warning indicator lamp
The remote anti-theft personality (RAP)/central security module controls the following features: ^
remote keyless entry
^ computer-operated locks
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation >
System Description > Page 883
Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How
Does It Work?)
Central Security Module
The central security module controls the following features:
^ remote key less entry system
^ computer-operated lock system
Generic Electronic Module (Gem)
NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be
reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal.
The GEM receives inputs and delivers outputs to a majority of the electronically controlled features
of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in
the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool
through the ISO 9141 communication network. The GEM controls the following features:
^ front wiper and washer
^ warning chime
^ battery saver
^ illuminated entry and interior lighting
^ driver one-touch down power window (optional)
^ battery saver relay
^ door ajar warning indicator lamp
^ safety belt warning indicator lamp
Remote Anti-Theft Personality (RAP) Module
The Remote Anti-theft Personality (RAP) module controls the following features:
^ remote keyless entry system
^ computer-operated lock system
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview
Central Security Module (CSM)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 18 (25 A)
- 11 (7.5 A)
^ Wiring harness Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module
Communications Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the central security module.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Generic Electronic Module (GEM)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: -
10 (7.5A)
- 20 (7.5A)
- 25 (7.5A)
- 28 (7.5A)
^ Wiring harness
^ Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module
Communications Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the GEM.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Remote Anti-Theft Personality (RAP) Module
1. Verify the customer concern by operating the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 886
2. Visually inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 18 (25A)
- 11 (7.5A)
^ Wiring harness
^ Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications
Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test C.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the central security module.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 887
Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated
Procedures
DTC Chart B1213 - B1322
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 888
DTC Chart B1322 - B1345
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 889
DTC Chart B1347 - B1450
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 890
DTC Chart B1453 - B1602
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 891
DTC Chart B1610 - B1932
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 892
DTC Index B1933 - B2477
DTC Index B2477 - C1230
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 893
C1233 - P1826
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 894
P1827 - U2018
..
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 895
Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures
Symptom Chart
Symptom Chart
Symptom Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 896
Multifunction Electronic Control Modules: Pinpoint Tests
B1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 897
B1 - B2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 898
A1 - A2
A2
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 899
C1
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 900
C1 - C2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central
Security Module
Multifunction Electronic Control Modules: Service and Repair Central Security Module
REMOVAL
CAUTION: Prior to removal of the module, it is necessary to upload module configuration
information to the appropriate diagnostic equipment. This information needs to be downloaded into
the new module once installed.
1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel.
3. Disconnect the electrical connectors.
4. Remove the central security module.
1 Remove the bolts.
2 Remove the central security module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central
Security Module > Page 903
Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP)
Module
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel.
3. Disconnect the electrical connectors.
4. Remove the RAP module.
1 Remove the bolts.
2 Remove the RAP module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central
Security Module > Page 904
Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload
module configuration information to the diagnostic tool. This information needs to be downloaded
into, the new module once installed.
2. Remove the radio chassis. Refer to Radio, Stereo, and Compact Disc.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
4. Remove the GEM.
1 Remove the bolt.
2 Disconnect the electrical connectors from the GEM.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download module configuration
information from the appropriate diagnostic tool into the new module.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Page 905
Multifunction Electronic Control Modules: Tools and Equipment
Special Tool(s)
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations
Keyless Entry Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 911
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 912
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 913
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 914
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 915
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 916
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 917
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 918
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 919
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 920
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 921
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 922
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 923
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 924
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 925
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 926
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 927
Keyless Entry Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 928
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 929
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 930
Keyless Entry Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 931
Keyless Entry Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Page 932
Keyless Entry Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Keyless Entry Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 939
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 940
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 941
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 942
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 943
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 944
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 945
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 946
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 947
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 948
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 949
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 950
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 951
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 952
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 953
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 954
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 955
Keyless Entry Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 956
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 957
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 958
Keyless Entry Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 959
Keyless Entry Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 960
Keyless Entry Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Locations
Power Door Lock Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions
Power Door Lock Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 966
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 967
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 968
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 969
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 970
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 971
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 972
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 973
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 974
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 975
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 976
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 977
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 978
Symbols
Symbols
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 979
Symbols
Symbols
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 980
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 981
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 982
Power Door Lock Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 983
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 984
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 985
Power Door Lock Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 986
Power Door Lock Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Page 987
Power Door Lock Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Driver Door Unlock Relay
Power Door Lock Relay: Locations Driver Door Unlock Relay
Diagram 700-01-00-6
Diagram 700-01-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Driver Door Unlock Relay > Page 992
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Driver Door Unlock Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Driver Door Unlock Relay > Page 995
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Driver Door Unlock Relay > Page 996
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Page 997
Power Door Lock Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Component Information > Diagrams > Page 998
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 1002
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control
Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set
Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON DTCB2607 May Be
Set
Article No. 01-6-1
04/02/01
^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
FORD: 2001 EXPLORER
ISSUE
The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607
may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp
may remain on or may illuminate intermittently. This may be due to the ABS module remaining
active when the engine is cranked and both blower motors are on.
ACTION
Replace the ABS module with an updated module if existing module is the original design, and
check for proper circuit grounding. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
It the ABS lamp is on intermittently:
1. Replace the ABS module.
a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Test drive vehicle to verify repair.
If the ABS lamp is on continuously:
1. Replace the ABS module.
a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 3.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control
Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 1012
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
3. Verify if the vehicle is a 4X4 or 4X2.
^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded.
^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary.
4. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 5.
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 301000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set
Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON
DTCB2607 May Be Set
Article No. 01-6-1
04/02/01
^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
FORD: 2001 EXPLORER
ISSUE
The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607
may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp
may remain on or may illuminate intermittently. This may be due to the ABS module remaining
active when the engine is cranked and both blower motors are on.
ACTION
Replace the ABS module with an updated module if existing module is the original design, and
check for proper circuit grounding. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
It the ABS lamp is on intermittently:
1. Replace the ABS module.
a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Test drive vehicle to verify repair.
If the ABS lamp is on continuously:
1. Replace the ABS module.
a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 3.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 1018
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
3. Verify if the vehicle is a 4X4 or 4X2.
^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded.
^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary.
4. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 5.
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 301000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 1019
Electronic Brake Control Module: Specifications
Control module bolts 13 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 1020
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 1021
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 1022
Electronic Brake Control Module: Description and Operation
Anti-Lock Brake Control Module
NOTE: The new anti-lock brake control module must be reconfigured upon installation.
The anti-lock brake control module is mounted to the HCU. It is an on-board diagnostic,
non-repairable unit consisting of two microprocessors and the necessary circuitry for their
operation. The anti-lock brake control module monitors system operation during normal driving as
well as during anti-lock braking. Anti-lock brake module operation is as follows: ^
Under normal driving conditions, the microprocessor produces short test pulses to the solenoid
valves that check the electrical system without any mechanical reaction.
^ Impending wheel lock conditions trigger signals from the anti-lock brake control module that open
and close the appropriate solenoid valves. This results in moderate pulsations in the brake pedal.
During normal braking, the brake pedal feel will be identical to a standard brake system. Most faults
that occur in the anti-lock brake system will be stored as a diagnostic trouble code (DTC) in the
keep-alive memory of the anti-lock brake control module. The DTCs can be retrieved by following
the on-board diagnostic procedures.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 1023
Electronic Brake Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 1024
Electronic Brake Control Module: Service and Repair
Module-Anti-Lock Brake Control
Removal and Installation
1. Disconnect the battery ground cable.
2. Disconnect the electrical connectors.
3. Remove the anti-lock brake control module.
1 Remove the bolts.
2 Remove the anti-lock brake control module.
4. CAUTION: Once the new module is installed, the module configuration information may have to
be entered.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations
Blower Motor Relay: Locations
Diagram 700-01-00-1
Diagram 700-01-00-5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 1029
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 1030
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > High Speed Fan Control Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > High Speed Fan Control Relay > Page 1033
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Page 1034
Blower Motor Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Page 1035
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1039
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1040
Compressor Clutch Relay: Description and Operation
WIDE OPEN THROTTLE A/C CUT-OFF
The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally
open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)).
If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant
temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C
(WAC) output, closing the relay contacts and sending voltage to the A/C clutch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1041
Compressor Clutch Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1042
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips
Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 1047
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 1048
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Locations
Audible Warning Device Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Audible Warning Device Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1055
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1056
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1057
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1058
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1059
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1060
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1061
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1062
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1063
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1064
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1065
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1066
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1067
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1068
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1069
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1070
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1071
Audible Warning Device Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1072
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1073
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1074
Audible Warning Device Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1075
Audible Warning Device Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Page 1076
Audible Warning Device Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1085
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1086
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1087
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1093
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1094
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1095
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Locations > Page 1099
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1104
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1105
Battery Discharge Protection Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1106
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams > Page 1110
Courtesy Lamp Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams > Page 1111
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations > Page 1115
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations > Page 1116
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the Daytime Running Lamps (DRL) control module.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Fog Lamp Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Fog Lamp Relay > Page 1122
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Page 1123
Fog/Driving Lamp Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Page 1124
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 1128
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 1129
Hazard Flasher Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 1130
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1134
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1135
Horn Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1136
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Locations
Interior Lighting Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1142
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1143
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Component Information > Diagrams > Diagram Information and Instructions > Page 1144
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1145
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1146
Circuit Identification Chart
System Codes Chart
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1147
Sample Diagrams
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1148
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1149
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1150
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1151
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1152
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1153
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1154
Symbols
Symbols
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1155
Symbols
Symbols
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Component Information > Diagrams > Diagram Information and Instructions > Page 1156
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Component Information > Diagrams > Diagram Information and Instructions > Page 1157
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Component Information > Diagrams > Diagram Information and Instructions > Page 1158
Interior Lighting Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1159
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1160
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1161
Interior Lighting Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1162
Interior Lighting Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Page 1163
Interior Lighting Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations
Diagram 700-01-00-6
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations > Page 1167
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations > Page 1168
Interior Lighting Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations > Page 1169
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Diagram 700-01-00-7
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Diagrams > Early Production
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Diagrams > Early Production > Page 1175
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Early Production
Parking Lamp Relay: Testing and Inspection Early Production
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Early Production > Page 1178
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Early Production > Page 1179
Parking Lamp Relay: Testing and Inspection Late Production
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Early Production > Page 1180
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Page 1184
Trailer Lighting Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Page 1185
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Diagrams
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Diagrams > Page 1189
Turn Signal Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Diagrams > Page 1190
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection > Page 1195
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection > Page 1199
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1204
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1205
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1206
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1207
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1208
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1209
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1210
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1211
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1212
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1213
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1214
Relay Box: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1215
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1216
Relay Box: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1217
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1218
Relay Box: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1219
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1222
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1223
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1224
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1225
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1226
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1227
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1228
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1229
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1230
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1231
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1232
Relay Box: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1233
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1234
Relay Box: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1235
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1236
Relay Box: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1237
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC
Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC
Replacement > Page 1248
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC
Replacement > Page 1249
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC
Replacement > Page 1250
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's
Powertrain Control Module: Customer Interest Instrument Panel - `Buzz' At Low Engine RPM's
Article No. 01-4-10
03/05/01
NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD
AT IDLE OR LOW SPEED DRIVING
FORD: 2001 EXPLORER
ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a
"buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving
with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control
Module (PCM) resonating against the heat shield that is located inside the PCM.
ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the
following Service Procedure for details.
SERVICE PROCEDURE
1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section
303-14 for removal procedure.
2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following
dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the
Rotunda Squeak and Rattle Kit, part number 164-R4900.
3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the
top surface of the module at the rear center of the module. This will dampen the buzz noise from
the PCM outer case. (Figure 1).
4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure.
5. Test drive vehicle to verify that the noise is corrected.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's >
Page 1255
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 702000, 702100, 702300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine
Controls - General PCM Programming Procedures
Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
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Controls - General PCM Programming Procedures > Page 1261
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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Controls - General PCM Programming Procedures > Page 1262
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine
Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
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Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine
Controls - DTC P1635 Set After PCM/IC Replacement > Page 1267
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine
Controls - DTC P1635 Set After PCM/IC Replacement > Page 1268
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
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Controls - DTC P1635 Set After PCM/IC Replacement > Page 1269
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
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Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 >
Instrument Panel - `Buzz' At Low Engine RPM's
Powertrain Control Module: All Technical Service Bulletins Instrument Panel - `Buzz' At Low
Engine RPM's
Article No. 01-4-10
03/05/01
NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD
AT IDLE OR LOW SPEED DRIVING
FORD: 2001 EXPLORER
ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a
"buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving
with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control
Module (PCM) resonating against the heat shield that is located inside the PCM.
ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the
following Service Procedure for details.
SERVICE PROCEDURE
1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section
303-14 for removal procedure.
2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following
dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the
Rotunda Squeak and Rattle Kit, part number 164-R4900.
3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the
top surface of the module at the rear center of the module. This will dampen the buzz noise from
the PCM outer case. (Figure 1).
4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure.
5. Test drive vehicle to verify that the noise is corrected.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
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Instrument Panel - `Buzz' At Low Engine RPM's > Page 1274
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 702000, 702100, 702300
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Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine
Controls - General PCM Programming Procedures
Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine
Controls - General PCM Programming Procedures > Page 1280
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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Controls - General PCM Programming Procedures > Page 1281
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Technical Service Bulletins > Page 1282
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Technical Service Bulletins > Page 1283
Powertrain Control Module: Diagrams
Part 1
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Technical Service Bulletins > Page 1284
Part 2
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Technical Service Bulletins > Page 1285
Powertrain Control Module: Description and Operation
POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO)
The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem
generates vehicle speed information for distribution to the vehicle's electrical/electronic modules
and subsystems that require vehicle speed data. This subsystem senses the transmission output
shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired
signal or as a multiplexed data message.
The key features of the PCM-VSO system are to:
^ Infer vehicle movement from the output shaft sensor signal
^ Convert transmission output shaft rotational information to vehicle speed information
^ Compensate for tire size and axle ratio with a programmed calibration variable
^ Utilize a transfer case sensor for four wheel drive applications
^ Distribute vehicle speed information as a multiplexed message and/or an analog signal
The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft
Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is
sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per
mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into
the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing
changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information
can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM,
or by Speed and Odometer SCP multiplexed data messages.
The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT.
Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for
speed and distance data are transmitted as separate SCP messages over the SCP multiplex link.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory
Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read
Only Memory
Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM
Description
Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an
Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the
vehicle strategy including calibration information specific to the vehicle and is capable of being
reprogrammed or reflashed repeatedly.
As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM as under Programming the VID Block for
a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block
not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can
also be tailored to accommodate various hardware changes made to the vehicle since production.
Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of
Acceptable Range. This is described under Making Changes to the VID Block and also under
Making Changes to the PCM Calibration. The VID block contains many items used by the strategy
for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane,
fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel
drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle
hardware and supported by the VID block will be displayed on the scan tool.
When changing items in the VID block, the strategy will place range limits on certain items such as
tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When
this limit is reached, the scan tool will display a message indicating the need to flash the PCM
again to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other
Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic
tool manufacturers users manual for details.
Programming the VID Block for a Replacement PCM
A new PCM will contain the latest strategy and calibration level for a particular vehicle. However,
the VID block will be blank and will need programming. There are two procedures available. The
first is an automatic data transfer from the old PCM to the new PCM and the second is manual data
entry into the new PCM.
Automatic data transfer will be performed if the old PCM is capable of communicating. This is done
by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The
stored data can now be downloaded to the new PCM after it has been replaced.
Manual data entry must be performed if the old module is damaged and is incapable of
communicating. Remove and replace the old PCM. You may be instructed to contact the "AS
BUILT" data center for the information needed to manually update the VID block with the scan tool.
Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M
technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed
World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or
"Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 1288
Powertrain Control Module: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the Powertrain Control Module (PCM) electrical connector.
3. Remove the nuts and the PCM cover.
4. Remove the PCM.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1292
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1293
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1294
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation
Air Injection Pump Relay: Description and Operation
SOLID STATE RELAY
Solid State Relay
The solid state relay (Figure 124) switches the high current required for operation of the electric
AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1303
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1304
Fuel Pump Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1305
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Diagram 700-01-00-1
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1309
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1310
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1311
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1317
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1318
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1320
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
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DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1322
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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1323
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Component Information > Technical Service Bulletins > Page 1324
Air Bag Control Module: Specifications
Restraints Control Module Bolts 12 Nm
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Component Information > Technical Service Bulletins > Page 1325
Air Bag Control Module: Locations
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
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Component Information > Technical Service Bulletins > Page 1326
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Component Information > Technical Service Bulletins > Page 1327
Air Bag Control Module: Diagrams
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Component Information > Technical Service Bulletins > Page 1328
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Technician Safety Information
Air Bag Control Module: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
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Component Information > Service Precautions > Technician Safety Information > Page 1331
Air Bag Control Module: Vehicle Damage Warnings
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
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Component Information > Service Precautions > Page 1332
Air Bag Control Module: Description and Operation
The Restraints Control Module (RCM) carries out the following functions:
^ signals the inflators to deploy the air bags in the event of a deployable crash.
^ monitors the air bag supplemental restraint system (SRS) for faults.
^ illuminates the air bag indicator if a fault is detected.
^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic
Trouble Codes (DTCs).
^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safing sensor is internal to the RCM and is not serviced separately.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the RUN position, the RCM will flash the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the
LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also
communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag
indicator does not function, and the system detects a fault condition, the RCM will signal the GEM
to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is
heard, the SRS and the air bag indicator require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors determine that a deployment is required. The backup power supply will deplete its
stored energy approximately one minute after the battery ground cable is disconnected.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Page 1333
Air Bag Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Air Bag Systems; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module
Air Bag Control Module: Service and Repair Restraints Control Module
With Side Air Bags
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1336
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1337
4. Remove the retaining bolts and remove the lower steering column opening finish panel
reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1338
SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR
STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS
DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD
LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1339
15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18.
Reconnect the battery ground cable. 19. With the restraint system diagnostic tools installed at all
deployable devices, prove out the air bag system. See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming
20. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
21. Remove the full floor console.
Vehicles with a restraint control module cover
22. Remove the mat, the screws and the Restraint Control Module (RCM) cover.
23. Remove the right-hand side RCM retaining bolts
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1340
24. Remove the RCM.
1 Slide and disengage the two RCM electrical connector locking clips.
2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect.
3 Remove the retaining bolt.
4 Remove the RCM.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Position the RCM to the center tunnel area and install the three bolts hand-tight.
WARNING: ^
THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and
safety belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1341
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Tighten the right-hand side RCM bolts to specification.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Connect the RCM.
1 Tighten the bolt to specification.
2 Connect the RCM electrical connectors.
3 Slide and engage the RCM electrical connector locking clips.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all
deployable devices, prove out the air bag system.
6. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1342
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
7. Install the full floor console.
Vehicles with a restraint control module cover
8. Position the RCM cover. Install the screws and the mat.
9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
10. Connect the clockspring electrical connector at the base of the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1343
11. Position the lower steering column opening finish panel reinforcement and install the bolts.
12. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top seating
the retaining clips.
2 Install the screws.
13. Position the hood release handle and install the screws.
14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1344
15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. Move and tilt
the front seats to their highest and most forward position. 18. Disconnect the battery ground cable
and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
19. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
21. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1345
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
22. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 23.
Connect the battery ground cable. 24. Position the front seats rearward. 25. Connect the battery
ground cable. 26. With all the diagnostic tools removed, prove out the air bag system. See: Body
and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Without Side Air Bags
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1346
REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1347
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
4. Remove the retaining bolts and remove the lower steering column opening finish panel
reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1348
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Reconnect the battery ground cable.
10. With the restraint system diagnostic tools installed at all deployable devices, prove out the air
bag system. See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming
11. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
12. Remove the full floor console.
Vehicles with a restraint control module cover
13. Remove the mat, the screws and the Restraint Control Module (RCM) cover.
14. Remove the right-hand side RCM retaining bolts
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1349
15. Remove the RCM.
1 Slide and disengage the two RCM electrical connector locking clips.
2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect.
3 Remove the retaining bolt.
4 Remove the RCM.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Position the RCM to the center tunnel area and install the three bolts hand-tight.
WARNING: ^
THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and
safety belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1350
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Tighten the right-hand side RCM bolts to specification.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Connect the RCM.
1 Tighten the bolt to specification.
2 Connect the RCM electrical connectors.
3 Slide and engage the RCM electrical connector locking clips.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
4. Connect the battery ground cable.
5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air
bag system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1351
6. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
7. Install the full floor console.
Vehicles with a restraint control module cover
8. Position the RCM cover. Install the screws and the mat.
9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1352
10. Connect the clockspring electrical connector at the base of the steering column.
11. Position the lower steering column opening finish panel reinforcement and install the bolts.
12. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top seating
the retaining clips.
2 Install the screws.
13. Position the hood release handle and install the screws.
14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1353
VEHICLE SAFETY STANDARDS.
15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. With all the
diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument
Panel/Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 1354
Air Bag Control Module: Service and Repair Weld Nut Repair
"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control
Module (RCM) and Side Crash Sensor before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut
Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts
must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and
Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification. Refer to Torque Specifications.
Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM)
and Side Crash Sensor before proceeding with the repair.
^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld
Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-S190).
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Component Information > Service and Repair > Restraints Control Module > Page 1355
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification. Refer to Torque Specifications.
Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE
LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Refer to Torque Specifications.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Page 1356
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1361
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1362
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1363
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1364
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1365
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1366
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1367
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay >
Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation
Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation
Article No. 01-2-5
2/05/01
^ TRIM - SEAT BELT WARNING SYSTEM - "BELT
^ MINDER" FUNCTION - OPERATION AND SERVICE
^ TIPS
^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND
^ SERVICE TIPS
FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION,
F-150, RANGER, WINDSTAR 2001 EXPLORER
LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR
MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER
ISSUE
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning
function. This feature provides additional reminders to the driver that the driver's safety belt is
unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the
instrument cluster.
ACTION
Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by
performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt
Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following
Service Procedure.
SERVICE PROCEDURE
To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure.
1. Establish a session for the vehicle.
2. Select the "Toolbox" icon.
3. Select "Module Programming" and press the "Tick" mark.
4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark.
5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark.
6. WDS will display "Configuration Complete", then press the "Tick" mark.
NOTE:
IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT
LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH
HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT
WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS
EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE
SAFETY BELT IS BUCKLED.
NOTE:
WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND
CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT
WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND
FOR 4-8 SECONDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay >
Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 1372
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 104000, 204000, 206000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1377
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1378
Starter Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1379
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1384
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1385
Heated Glass Element Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1386
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Locations
Power Window Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions
Power Window Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1392
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1393
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1394
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1395
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1396
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1397
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1398
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1399
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1400
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1401
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1402
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1403
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1404
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1405
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1406
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1407
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1408
Power Window Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1409
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1411
Power Window Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1412
Power Window Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Page 1413
Power Window Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Diagrams > Window Safety Relay
Power Window Relay: Diagrams Window Safety Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Diagrams > Window Safety Relay > Page 1419
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Window Safety Relay
Power Window Relay: Testing and Inspection Window Safety Relay
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Window Safety Relay > Page 1422
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Window Safety Relay > Page 1423
Power Window Relay: Testing and Inspection One-Touch Window Relay
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Window Safety Relay > Page 1424
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Locations
Windshield Washer Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1431
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1432
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1433
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1434
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1435
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1436
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1437
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1438
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1439
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1440
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1441
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1442
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1443
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1444
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1445
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1446
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1447
Windshield Washer Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1448
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1449
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1450
Windshield Washer Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1451
Windshield Washer Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Page 1452
Windshield Washer Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Locations
Diagram 700-01-00-1
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Diagrams > Windshield Washer Relay, Front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Diagrams > Windshield Washer Relay, Front > Page 1458
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Diagrams > Page 1459
Windshield Washer Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Diagrams > Page 1460
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations
Wiper Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions
Wiper Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1466
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1467
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1468
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1469
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1470
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1471
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1472
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1473
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1474
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1475
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1476
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1477
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1478
Symbols
Symbols
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1479
Symbols
Symbols
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1480
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1481
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1482
Wiper Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1483
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1484
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1485
Wiper Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1486
Wiper Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Page 1487
Wiper Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Wiper High/Low Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Wiper High/Low Relay > Page 1493
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Wiper High/Low Relay > Page 1494
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Wiper High/Low Relay > Page 1495
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Page 1496
Wiper Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Page 1497
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page
1505
OASIS CODES: 201000, 201200
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Driver Side > Page 1510
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Door Lock Switch, Driver Side
Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1513
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1514
Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1515
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 1519
Power Mirror Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 1520
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams
Power Seat Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service Precautions > Technician Safety Information
Power Seat Switch: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR
BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
- TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service Precautions > Technician Safety Information > Page 1526
Power Seat Switch: Vehicle Damage Warnings
CAUTION:
- Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat
not secured in the vehicle may result in damaged components.
- To prevent damage to the side shield, the clips must be depressed in order to release the side
shield from the cushion pan.
- Use care when disconnecting the seat cushion side shield from the seat cushion frame so the
tabs on the seat cushion side shield are not damaged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Except Side Air Bags
Power Seat Switch: Testing and Inspection Except Side Air Bags
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Except Side Air Bags > Page 1529
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Except Side Air Bags > Page 1530
Power Seat Switch: Testing and Inspection With Side Air Bags
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Except Side Air Bags > Page 1531
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag
Power Seat Switch: Service and Repair With Side Air Bag
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR
BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1534
connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to
operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1535
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
8. Using the special tool, remove the safety belt buckle support bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1536
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1537
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1538
21. Disconnect the clockspring electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO
DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
26. Remove the lumbar support knob.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1539
27. Remove the rear side shield screw.
28. Release the side shield clips.
CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release
the side shield from the cushion pan.
29. Unhook the side shield from the seat latch.
30. Remove the side shield.
1 Disconnect the electrical connector.
2 Remove the side shield.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1540
31. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS OR THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1541
1. Install the 6-way power seat switch.
1 Install the 6-way power seat switch.
2 Install the screws.
2. Install the side shield.
1 Install the side shield.
2 Install the electrical connector.
3. Hook the side shield to the seat latch.
4. Install the side shield clips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1542
5. Install the rear side shield screw.
6. Install the lumbar support knob. 7. Position the driver seat into the vehicle. Install the four seat
track to floor bolts and hand-tighten them.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
8. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1543
9. Connect the driver seat side air bag and power seat (if equipped) electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
3 Tie-strap the wire harness.
10. Connect the battery ground cable. 11. Position the driver seat rearward. 12. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
13. Tighten the driver seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
14. Move and tilt the driver seat to its highest and most forward position.
15. Tighten the driver seat rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
16. Install the driver seat rear track bolt covers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1544
17. Connect the safety belt warning indicator electrical connector.
18. Using the special tool, install the safety belt buckle support bolt.
19. Install the safety belt buckle support bolt cover. 20. Position the driver seat rearward. 21.
Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO
DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
22. Position the passenger seat forward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1545
23. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
24. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 25.
Position the passenger seat rearward.
26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
27. Install the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1546
28. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
29. Connect the clockspring electrical connector at the base of the steering column.
30. Position the lower steering column opening finish panel reinforcement and install the bolts.
31. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1547
32. Position the hood release handle and install the screws. 33. Connect the battery ground cable.
34. With all the diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
35. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1548
Power Seat Switch: Service and Repair Without Side Air Bag
REMOVAL
1. Remove the front seat.
2. Remove the lumbar control knob, if equipped.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
5. Remove the front seat cushion side shield screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > With Side Air Bag > Page 1549
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Remove the front seat cushion side shield.
8. Remove the 6-way power seat switch.
- Remove the screws, then remove the 6-way power seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Page 1550
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Diagrams > Page 1554
Sunroof / Moonroof Switch: Service and Repair
REMOVAL
1. Position the overhead console aside.
2. Remove the roof opening panel control switch.
1 Remove the screws.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Ajar Switch
Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Ajar Switch > Page 1559
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 1560
Trunk / Liftgate Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 1561
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 1566
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 1567
Brake Fluid Level Sensor/Switch: Description and Operation
Warning Switch, Brake Fluid Level
The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder
reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the
brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to
a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning
indicator to illuminate. Loss of brake fluid will cause this system to activate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations > Page 1571
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > Front
Wheel Speed Sensor: Specifications
Front anti-lock brake sensor bolt (4x2) 8.5 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > Front > Page 1579
Wheel Speed Sensor: Specifications
Rear anti-lock brake sensor bolt 20 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Left front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Left front > Page 1582
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 1585
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 1586
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Page 1587
Wheel Speed Sensor: Description and Operation
Anti-Lock Brake Sensor
NOTE: Any time an anti-lock brake sensor is removed, thoroughly clean the mounting surfaces. On
front anti-lock brake sensors, apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease
E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.
The anti-lock brake system uses three variable-reluctance sensors to determine vehicle speed. The
anti-lock brake sensors operate on magnetic induction principle. As the teeth on the anti-lock brake
sensor indicator rotate past the stationary sensor, a signal proportional to the speed of the rotation
is generated and sent to the anti-lock brake control module through a twisted cable and shielded
wiring harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Rear Antilock Control
Wheel Speed Sensor: Service and Repair Rear Antilock Control
Sensor-Rear
Removal and Installation
1. Raise and support vehicle.
2. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake
sensor before removal.
Remove the rear anti-lock brake sensor. 1
Disconnect the rear anti-lock brake sensor electrical connector.
2 Remove the bolt.
3 Remove the rear anti-lock brake sensor.
3. NOTE: Thoroughly clean the mounting surface.
NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE
75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford
specification WSL-M2C192-A.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 1590
Wheel Speed Sensor: Service and Repair Sensor, Front
Sensor-Front 4x2
Removal and Installation
1. Raise and support the vehicle.
2. Disconnect the front anti-lock brake sensor wire from the vehicle frame.
1 Disconnect the electrical connector.
2 Unclip the front anti-lock brake sensor wire from the vehicle frame.
3. Remove the front anti-lock brake sensor.
1 Remove the bolt.
2 Remove the front anti-lock brake sensor.
4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply
High-Temperature 4x4 Front Axle and Wheel Bearing
Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 1591
Wheel Speed Sensor: Service and Repair Sensor, Rear
Sensor-Rear
Removal and Installation
NOTE: The rear anti-lock brake sensor indicator is attached to the differential case.
For additional information, refer to Transmission and Drivetrain; Differential.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 1597
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 1598
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
2. Remove the retaining clip and the ECT sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature Sensor > Page 1603
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 1607
Temperature Sensor (Gauge): Service and Repair
Sender Unit-Water Temperature Indicator
Removal and Installation
1. Partially drain the cooling system. 2. Remove the thermostat.
3. Disconnect the electrical connector.
4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal
procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1617
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1618
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1619
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1620
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1621
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1622
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1623
Attachment III - Technical Information
Table of Contents
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1624
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1625
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1626
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1627
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1628
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1629
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1630
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1631
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1632
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1633
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1634
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1635
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1636
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1637
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1638
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1639
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1640
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1641
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1642
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 >
Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 >
Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1647
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1653
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1654
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1655
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1656
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1657
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1658
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1659
Attachment III - Technical Information
Table of Contents
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1660
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1661
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1662
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1663
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1664
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1665
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1666
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1667
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1668
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1669
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1670
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1671
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1672
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1673
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1674
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1675
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1676
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1677
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1678
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control
Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1683
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Page 1684
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Service Precautions > Technician Safety Information
Brake Switch (Cruise Control): Technician Safety Information
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Service Precautions > Technician Safety Information > Page 1687
Brake Switch (Cruise Control): Vehicle Damage Warnings
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Service Precautions > Page 1688
Brake Switch (Cruise Control): Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the speed control deactivator switch electrical connector.
3. Remove the speed control deactivator switch.
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
INSTALLATION
1. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair
Cruise Control Switch: Service and Repair
REMOVAL
1. Remove the steering wheel.
2. Remove the screws and the steering wheel rear cover.
3. Remove the ribbon harness from the clips.
4. Disconnect the horn contact electrical connectors.
5. Remove the screws and the right side horn contact.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair > Page 1695
6. Remove the screws and the speed control switch assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component
Information > Service and Repair
Air Conditioning Switch: Service and Repair
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Diagrams
Blower Motor Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Diagrams > Page 1707
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Diagrams > Page 1708
Blower Motor Switch: Description and Operation
Function Selector Switch
The function selector switch combines a vacuum selector valve with two electrical switches to
supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit.
Temperature Control Switch
Temperature selection is accomplished with a potentiometer connected to the electric blend door.
Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a
corresponding movement on the air temperature that the air system will maintain.
Blower Motor Switch
The blower motor switch controls blower motor speed by adding or by passing resistors in the
heater blower motor switch resistor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Diagrams > Page 1709
Blower Motor Switch: Service and Repair
CLIMATE CONTROL ASSEMBLY-FRONT SWITCHES
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Locations > Page 1713
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Diagrams > A/C Pressure Switch
A/C High Pressure Switch Connector
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Diagrams > A/C Pressure Switch > Page 1716
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction
accumulator.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction pressure inside the suction accumulator to control the operation of the A/C
cycling switch.
- The electrical switch contacts open when the suction pressure drops, The contacts close when
the suction pressure rises. Refer to specifications regarding operating pressure(s).
- When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the
wide open throttle A/C cutoff relay.
- When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of air flow.
- It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the
A/C cycling switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 1719
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch
PCM Inputs
AIR CONDITIONING CYCLING SWITCH
The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or
ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will
turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling
switch, refer to Heating and Air Conditioning.
The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when
the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch
and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are
closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle
specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See:
Powertrain Management/Description and Operation/PCM Outputs
NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C
is requested. This information is received by the PCM through the BUS + and BUS - Standard
Corporate Protocol (SCP) communication.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 1720
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure
Switch
The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure
side of the A/C manifold and tube.
- A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises, the switch contacts open, disengaging the A/C
compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor. Refer to specifications regarding operating pressure(s).
- It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the
A/C pressure cutoff switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Testing and Inspection
Dimmer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Testing and Inspection > Page 1725
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pin 6 using a fused (10A) jumper to 12V DC power and pin 9 to
ground. Measure the voltage between pin 8 and pin 9 while rotating the thumbwell from full
illumination to no illumination. If the voltage smoothly decreases from near 12 volts to near 0 volts,
the illumination dimmer is okay. If not, replace the main light switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Driver Side
Door Switch: Diagrams Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Driver Side > Page 1730
Door Switch: Diagrams Passenger Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch
Door Switch: Service and Repair Door Ajar Switch
REMOVAL
1. Remove the door interior trim panel.
NOTE: Front door shown, rear door similar.
2. Position the watershield aside.
3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch.
- Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch > Page 1733
Door Switch: Service and Repair Door Ajar Switch-Liftgate
REMOVAL
1. Remove the liftgate latch.
2. Remove the liftgate latch ajar switch.
- Remove the screw.
INSTALLATION
1. To install, reverse the removal process.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Digital Transmission Range Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Digital Transmission Range Sensor > Page 1743
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position
Switch <--> [Brake Light Switch] > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position
Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 1747
Brake Pedal Position Switch: Description and Operation
BRAKE PEDAL POSITION SWITCH
Typical Brake Pedal Position Switch
The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the
transmission torque converter clutch and on some applications as an input to the idle speed control
for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery
positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch
signal is broadcast over the SCP link via another module to be received by the PCM.
On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all
stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor
in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has
failed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position
Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 1748
Brake Pedal Position Switch: Service and Repair
REMOVAL
1. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
2. Remove the BPP switch.
1 Remove the self-locking pin.
2 Remove the spacer.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Driver Side
Door Switch: Diagrams Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Driver Side > Page 1753
Door Switch: Diagrams Passenger Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch
Door Switch: Service and Repair Door Ajar Switch
REMOVAL
1. Remove the door interior trim panel.
NOTE: Front door shown, rear door similar.
2. Position the watershield aside.
3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch.
- Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch > Page 1756
Door Switch: Service and Repair Door Ajar Switch-Liftgate
REMOVAL
1. Remove the liftgate latch.
2. Remove the liftgate latch ajar switch.
- Remove the screw.
INSTALLATION
1. To install, reverse the removal process.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch
> Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch
> Component Information > Diagrams > Page 1760
Fog/Driving Lamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
3. Remove the fog lamp switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the fog lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams
Hazard Warning Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 1764
Hazard Warning Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 1765
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams
Headlamp Dimmer Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 1769
Headlamp Dimmer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 1770
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 1774
Headlamp Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 1775
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 1776
Headlamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel center finish panel.
1 Remove the screws.
2 Remove the instrument panel center finish panel. ^
Disconnect electrical connectors.
3. Remove the hood latch release handle.
1 Remove the screws.
2 Remove the hood latch release handle.
4. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 1777
5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the
column gear shift lever out of the way.
7. Position the cluster finish panel aside.
1 Remove the screws.
2 Position the cluster finish panel aside.
8. Remove the cluster finish panel.
1 Disconnect the electrical connectors and remove the headlamp switch knob.
2 Remove the cluster finish panel.
9. Remove the headlamp switch.
1 Remove the screws.
2 Remove the headlamp switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 1778
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Service and Repair
Horn Switch: Service and Repair
REMOVAL
1. Remove the driver side air bag.
2. Remove the switch.
1 Disconnect the horn wire (BK) from the switches.
2 Remove the screws and the switch.
INSTALLATION
1. To install, reverse the removal procedure.
^ Prove out the air bag system; refer to Air Bag Systems.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams
Turn Signal Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 1785
Turn Signal Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 1786
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 1787
Turn Signal Switch: Service and Repair
Multifunction Switch
Removal and Installation
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 1788
5. Remove the multifunction switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multifunction switch.
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch
> Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch
> Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 1793
OASIS CODES: 201000, 201200
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and
Operation
Absolute Pressure Sensor: Description and Operation
THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR
Thermal Manifold Absolute Pressure (TMAP) Sensor
The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold
Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is
currently not being used. The MAP part of the sensor measures intake manifold air absolute
pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air
Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP)
sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced
into the intake manifold.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Locations > Page 1802
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Locations > Page 1803
Mass Air Flow Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Locations > Page 1804
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Locations > Page 1805
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Loosen the air cleaner outlet tube clamp and position the tube aside.
3. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
1809
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
1810
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
1811
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 1815
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION SWITCH
Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches
The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch
pedal position and, in some manual transmission applications, both the clutch pedal engagement
position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference
Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP
signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed,
indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output
voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1
volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or
PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the
clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP
switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the
5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load
information in mass air flow and fuel calculations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 1819
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 1820
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
2. Remove the retaining clip and the ECT sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
1824
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
1825
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
1826
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Crankshaft Position (CKP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will
wear off after several engine revolutions.
^ Be sure the sensor wiring is routed away from the battery cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature Sensor > Page 1831
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions
Fuel Tank Pressure Sensor: Service Precautions
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
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Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure Sensor
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor
(Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles
equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank
pressure by forcing the system to purge.
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Fuel Tank Pressure Sensor: Service and Repair
REMOVAL
1. Remove the fuel tank.
2. Remove the fuel tank pressure sensor.
1 Disconnect the electrical connector.
2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the
fuel tank.
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions
System/Testing and Inspection/Component Tests and General Diagnostics/Component
Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emissions repair verification drive cycle. See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
Repair Verification Drive Cycle
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1841
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE SENSOR
Intake Air Temperature (IAT)
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals
The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type
(Figure 37), are thermistor devices in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
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Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel spark and MAF.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above.
However, one is located before the supercharger at the air cleaner for standard OBD II/cold
weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control border-line spark and to help determine intercooler
efficiency.
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Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold.
3. Remove the KS.
1 Remove the bolt.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1852
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Diagrams > Diagram Information and Instructions
Heated Oxygen Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Circuit Identification Chart
System Codes Chart
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Sample Diagrams
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Diagrams > Diagram Information and Instructions > Page 1876
Sample Diagram
Sample Diagram
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Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Circuit Identification Chart
SYSTEM CODES CHART
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SAMPLE DIAGRAMS
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Sample Diagram
Sample Diagram
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Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Symbols
Symbols
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Symbols
Symbols
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Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Heated Oxygen Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Heated Oxygen Sensor: Connector Views
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Description and Operation > Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor Monitor
The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S
sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream
HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean
to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper
output voltage. The following illustration shows that input is required from the Engine Coolant
Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air
Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel
System Monitor and Misfire Detection Monitor must also have completed successfully before the
HO2S Monitor is enabled.
1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel
ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich
of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor
evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper
function.
2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response
frequency are checked. Excessive voltage is
determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A
fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S
heater circuit fault is determined by turning the heater on and off and looking for a corresponding
change in the Output State Monitor (OSM) and by measuring the current going through the heater
circuit. The HO2S Monitor DTCs can be categorized as follows:
The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130,
P1131, P1132, P1150, P1151 and P1152.
The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153.
The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151
and P0156.
The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and
P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in
on-demand is DTC P1127.
The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129.
3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive
drive cycles.
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Heated Oxygen Sensor: Description and Operation PCM Inputs
HEATED OXYGEN SENSOR
Heated Oxygen Sensor (HO2S)
The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and
produces a variable voltage according to the amount of oxygen detected. A high concentration of
oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low
concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The
HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near
stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop
operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will
complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater
and heater control system are installed on some vehicles. The high power heater reaches closed
loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty
cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style
3.3 ohm heater.
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Description and Operation > Page 1895
Heated Oxygen Sensor: Service and Repair
Socket, Exhaust Gas Oxygen Sensor
SPECIAL TOOL(S)
REMOVAL
1. Raise and support the vehicle. 2. Remove the Three Way Catalytic Converter (TWC).
3. Using the special tool, remove the HO2S.
NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S.
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Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Page 1896
Socket, Exhaust Gas Oxygen Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 1905
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 1906
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 1907
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 1908
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 1909
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1915
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1916
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1917
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1918
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1919
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1924
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1925
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1926
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1932
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1933
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1934
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 1935
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 1936
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 1937
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 1938
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 1939
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR).
1 Disconnect the electrical connector.
2 Disconnect the hoses.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1943
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > PCM Inputs > Page 1946
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 1947
Throttle Position Sensor: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Remove the Throttle Position (TP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts and the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 1951
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 1952
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 1953
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 1954
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 1955
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor Bolt 98 - 115 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page
1959
Vehicle Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
Typical Vehicle Speed Sensor (VSS)
The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that
generates a waveform with a frequency that is proportional to the speed of the vehicle. If the
vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As
the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM
uses the frequency signal generated by the VSS (and other inputs) to control such parameters as
fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch
scheduling.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page
1960
Vehicle Speed Sensor: Service and Repair
Intermediate Shaft Speed (ISS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector.
3. Remove ISS sensor.
1. Remove the ISS sensor screw. 2. Remove the ISS sensor from the transmission.
^ Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the ISS sensor into the transmission. 2. Tighten ISS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page
1961
2. Connect ISS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1971
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1972
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1973
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1974
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1975
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 1981
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 1982
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 1983
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 1984
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 1985
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1990
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1991
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1992
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
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NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
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Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 1999
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
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Disclaimer
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Service Bulletins > Page 2003
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
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Service Bulletins > Page 2004
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
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Service Bulletins > Page 2005
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR).
1 Disconnect the electrical connector.
2 Disconnect the hoses.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations
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Locations > Page 2010
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Locations > Page 2011
Mass Air Flow Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
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Locations > Page 2012
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
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Locations > Page 2013
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Loosen the air cleaner outlet tube clamp and position the tube aside.
3. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
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Operation
Fuel Pressure Sensor/Switch: Description and Operation
FUEL RAIL PRESSURE SENSOR
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which
resistance changes with pressure. The electrical resistance of a strain gauge increases as
pressure increases, and decreases as pressure decreases. The varying resistance affects the
voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding
to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel
rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel
system. The differential fuel/intake manifold pressure together with measured fuel temperature
provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature
feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump
sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to
decrease.
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Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
Inertia Fuel Shutoff Switch
The Inertia Fuel Shutoff (IFS) switch is on the RH A-pillar lower trim panel.
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Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump.
The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel
ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the
magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the
switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset
before restarting the vehicle. Refer to the Owner Guide for the location of the IFS.
Inertia Fuel Shutoff (IFS) Switch
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Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect
the electrical connector.
3. Remove the bolts and remove the IFS switch.
INSTALLATION
1. To install, reverse the removal procedure.
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> PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
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> PCM Inputs > Page 2029
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
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> Page 2030
Throttle Position Sensor: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Remove the Throttle Position (TP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts and the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2036
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
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Camshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2042
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Crankshaft Position (CKP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will
wear off after several engine revolutions.
^ Be sure the sensor wiring is routed away from the battery cable.
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> Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder-Functional Lock Cylinder
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
3. To install, reverse the removal procedure.
^ Verify ignition switch lock cylinder operation.
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> Ignition Lock Cylinder - Functional > Page 2049
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder
Removal and Installation
1. NOTE: Make sure the front wheels are in the straight-ahead position.
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and
instructions in the steering wheel
removal and installation procedure.
Remove the steering wheel assembly.
3. Twist off the cap from the ignition switch cylinder.
4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock
repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to
build the new lock cylinder to the current key code of the vehicle.
Remove the ignition switch lock cylinder. ^
Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch
lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the
steering column.
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> Ignition Lock Cylinder - Functional > Page 2050
5. Remove the bearing retainer.
6. Remove the bearing and gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
7. To install, reverse the removal procedure.
^ Install a new ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
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Switches - Ignition System > Knock Sensor > Component Information > Diagrams
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Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2054
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold.
3. Remove the KS.
1 Remove the bolt.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Specifications
Impact Sensor: Specifications
Side Crash Sensor Bolts 12 Nm
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Component Information > Locations > Locations Views
Impact Sensor: Locations Locations Views
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
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Component Information > Locations > Locations Views > Page 2062
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Component Information > Locations > Locations Views > Page 2063
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Component Information > Diagrams > Right
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Component Information > Service Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR
CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN
WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND
BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER
OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE
RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
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Impact Sensor: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS
CRITICAL FOR PROPER SYSTEM OPERATION.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Page 2070
Impact Sensor: Description and Operation
WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR
CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN
WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND
BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER
OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE
RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
The SRS contains two sensors which are integral to the RCM. The RCM is mounted on the center
tunnel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation
Impact Sensor: Service and Repair Removal and Installation
Side Crash Sensor, Driver Side
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2073
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2074
4. Remove the bolts and the lower steering column opening finish panel reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2075
SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR
STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS
DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD
LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2076
15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the
diagnostic tools in place at all deployable devices, prove out the air bag system. See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming
19. Position the front seats to their most forward position. 20. Disconnect the battery ground cable
and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
21. Pull to release the retaining clips and remove the windshield side garnish molding.
22. Pull up to release the retaining clips and remove the front door scuff plate.
23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2077
24. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26.
Position the carpet aside at the front safety belt anchor.
27. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
28. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2078
3 Remove the quarter trim panel front screw.
29. Fold the rear seat into the load floor position.
30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
31. Remove the retractable cargo cover.
All Vehicles
32. Remove the rear safety belt guide.
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
3 Remove the rear safety belt guide.
33. Position the carpet aside at the rear safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2079
34. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
35. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
36. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
37. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2080
38. Remove the pin-type retainers from the quarter trim panel.
39. Slide the quarter trim panel forward and disengage it from the door jamb.
40. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness
out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2081
42. Position the side crash sensor with bracket away from the B-pillar.
1 Remove the bolts.
2 Position the side crash sensor with bracket away from the B-pillar.
43. Remove the side crash sensor.
1 Disconnect the electrical connector.
2 Remove the side crash sensor.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2082
removed from the vehicle and the restraint system diagnostic tools must be installed in the side
airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The
restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Connect the side crash sensor electrical connector.
1 Position the side crash sensor.
2 Connect the side crash sensor electrical connector.
2. Install the side crash sensor.
1 Position the side crash sensor with the bracket to the B-pillar.
2 Install the bolts.
WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery
ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all
deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest
and most forward position. 8. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2083
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
9. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbings through the openings in the quarter trim panel.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
10. Slide back and engage the edge of the quarter trim panel into the door jamb.
11. Install the quarter trim panel rear screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2084
12. Through the front door opening, install the quarter trim panel front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim panel front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
13. Install the pin-type retainers into the quarter trim panel.
14. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
15. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Vehicles with a rear power lock switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2085
16. Connect and install the rear power lock switch assembly into the rear quarter trim panel.
All vehicles
17. Position the washer on the rear safety belt guide bolt.
18. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
19. Fold the rear seat into the load floor position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2086
20. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
21. Reposition the carpet back over the floor.
22. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo covers
23. Install the retractable cargo cover.
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2087
24. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
25. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
26. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
27. Reposition the carpet at the front safety belt anchor.
28. Align the retaining clips and install the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2088
29. Align the retaining clips and install the windshield side garnish molding. 30. Reposition the rear
seat back upward.
31. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
32. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
33. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2089
VEHICLE SAFETY STANDARDS.
34. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 35.
Connect the battery ground cable. 36. Position the front seats rearward. 37. Disconnect the battery
ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
38. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
39. Install the passenger air bag module.
40. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2090
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
41. Connect the clockspring electrical connector at the base of the steering column.
42. Position the lower steering column opening finish panel reinforcement and install the bolts.
43. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
44. Position the hood release handle and install the screws. 45. Connect the battery ground cable.
46. With all the diagnostic tools removed, prove out the air bag system. See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2091
Panel/Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
47. Check the restraint system for correct operation.
Side Crash Sensor, Passenger Side
Special Tool(s)
SPECIAL SERVICE TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2092
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All Vehicles
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the passenger air bag module.
3. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
4. Remove the retaining screws and position the hood release handle out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2093
5. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
6. Remove the bolts and the lower steering column opening finish panel reinforcement.
7. Disconnect the clockspring electrical connector at the base of the steering column.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2094
DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING,
REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR
BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES,
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2095
15. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the
diagnostic tools in place at all deployable devices, prove out the air bag system. See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming
19. Position the front seats to their most forward position. 20. Disconnect the battery ground cable
and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
21. Pull to release the retaining clips and remove the windshield side garnish molding.
22. Pull up to release the retaining clips and remove the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2096
23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
24. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26.
Position the carpet aside at the front safety belt anchor.
27. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2097
28. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
3 Remove the quarter trim panel front screw.
29. Fold the rear seat into the load floor position.
30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
31. Remove the retractable cargo cover.
All Vehicles
32. Remove the rear safety belt guide.
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2098
3 Remove the rear safety belt guide.
33. Position the carpet aside at the rear safety belt anchor.
34. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
35. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
36. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
37. Remove the coat hook.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2099
1 Remove the screw.
2 Remove the coat hook.
38. Remove the pin-type retainers from the quarter trim panel.
39. Slide the quarter trim panel forward and disengage it from the door jamb.
40. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness
out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2100
42. Position the side crash sensor with the bracket away from the B-pillar.
1. Remove the bolts. 2. Position the side crash sensor with the bracket away from the B-pillar.
43. Remove the side crash sensor.
1 Disconnect the electrical connector.
2 Remove the side crash sensor.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM(SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2101
removed from the vehicle and the restraint system diagnostic tools must be installed in the side
airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The
restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Connect the side crash sensor electrical connector.
1 Position the side crash sensor.
2 Connect the side crash sensor electrical connector.
2. Install the side crash sensor.
1 Position the side crash sensor with the bracket to the B-pillar.
2 Install the bolts.
WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery
ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all
deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest
and most forward position. 8. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2102
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS. NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
9. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbing through the openings in the quarter trim panel.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
10. Slide back and engage the edge of the quarter trim panel into the door jamb.
11. Install the quarter trim panel rear screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2103
12. Through the front door opening, install the quarter trim panel front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim panel front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
13. Install the pin-type retainers into the quarter trim panel.
14. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
15. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2104
16. Position the washer on the rear safety belt guide bolt.
17. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
18. Fold the rear seat into the load floor position.
19. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
20. Reposition the carpet back over the floor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2105
21. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo covers
22. Install the retractable cargo cover.
All Vehicles
23. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
24. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2106
^ Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
25. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
26. Reposition the carpet at the front safety belt anchor.
27. Align the retaining clips and install the front door scuff plate.
28. Align the retaining clips and install the windshield side garnish molding. 29. Reposition the rear
seat back upward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2107
30. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
31. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
32. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
33. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2108
34. Connect the battery ground cable. 35. Position the front seats rearward. 36. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
37. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
38. Connect the clockspring electrical connector at the base of the steering column.
39. Position the lower steering column opening finish panel reinforcement and install the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2109
40. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
41. Position the hood release handle and install the screws.
42. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
43. Install the passenger air bag module. 44. Connect the battery ground cable. 45. With all the
diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument
Panel/Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
46. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2110
Impact Sensor: Service and Repair General Procedures
"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control
Module (RCM) and Side Crash Sensor before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut
Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts
must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and
Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification. Refer to Torque Specifications.
Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM)
and Side Crash Sensor before proceeding with the repair.
^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld
Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-S190).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2111
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification. Refer to Torque Specifications.
Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE
LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Refer to Torque Specifications.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Page 2112
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag >
Component Information > Description and Operation
Safing Sensor: Description and Operation
The safing sensor is internal to the RCM and is not serviced separately.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder-Functional Lock Cylinder
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
3. To install, reverse the removal procedure.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
2128
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder
Removal and Installation
1. NOTE: Make sure the front wheels are in the straight-ahead position.
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and
instructions in the steering wheel
removal and installation procedure.
Remove the steering wheel assembly.
3. Twist off the cap from the ignition switch cylinder.
4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock
repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to
build the new lock cylinder to the current key code of the vehicle.
Remove the ignition switch lock cylinder. ^
Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch
lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the
steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
2129
5. Remove the bearing retainer.
6. Remove the bearing and gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
7. To install, reverse the removal procedure.
^ Install a new ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 2133
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 2139
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 2140
Transmission Mode Switch: Service and Repair
Transmission Control Switch
Removal and Installation
1. Remove the Transmission Control Switch (TCS).
1. Remove the cover. 2. Remove the TCS.
2. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2144
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2145
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2146
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2147
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2148
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 2154
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 2155
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2158
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2159
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2160
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2161
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Instructions > Page 2162
Circuit Identification Chart
System Codes Chart
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2163
Sample Diagrams
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2164
Sample Diagram
Sample Diagram
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2165
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2166
Circuit Identification Chart
SYSTEM CODES CHART
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2167
SAMPLE DIAGRAMS
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2168
Sample Diagram
Sample Diagram
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2169
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2170
Symbols
Symbols
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2171
Symbols
Symbols
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2172
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2173
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2174
Transmission Speed Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2175
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2176
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2177
Transmission Speed Sensor: Connector Views
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2178
Diagram 29-4
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2179
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2180
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
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2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
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Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2187
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2188
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2189
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2190
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2191
Circuit Identification Chart
System Codes Chart
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2192
Sample Diagrams
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2193
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2194
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2195
Circuit Identification Chart
SYSTEM CODES CHART
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2196
SAMPLE DIAGRAMS
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2197
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2198
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2199
Symbols
Symbols
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2200
Symbols
Symbols
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2201
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2202
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2203
Transmission Temperature Sensor/Switch: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2204
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2205
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2206
Diagram 29-4
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 2207
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed
Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 2214
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 2215
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed
Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed
Sensor > Page 2218
Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 2219
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 2220
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 2221
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 2230
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 2231
Power Window Switch: Diagrams Window Adjust Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 2232
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2235
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2236
Power Window Switch: Testing and Inspection Power window Switch
Passenger Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2237
Left Rear Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2238
Right Rear Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2239
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 2240
Power Window Switch: Service and Repair
REMOVAL
NOTE: Driver window control switch shown, all others are similar.
Front door
1. Disconnect the battery ground cable.
All doors
2. Remove the window control switch panel.
^ Disconnect the electrical connectors.
3. Remove the window control switch.
^ Release the locking clips.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 2245
Windshield Washer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 2246
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Rear Window Wiper Disable Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 2251
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 2252
Wiper Switch: Diagrams Multi-Function Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 2253
Wiper Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 2254
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 2255
Wiper Switch: Service and Repair
REMOVAL
1. Remove the instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
2. Remove the rear wiper/washer switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the rear wiper/washer switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Alignment Procedure Revision
Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision
TSB 04-24-19
12/13/04
REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT
HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS
FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer
Sport Trac
ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar
and coil spring front suspensions has been discontinued. If the caster and camber settings need to
be adjusted, a washer must now be installed.
The right hand upper control arm design changed from a two piece design to a single piece design
during the 2003 model year. The single piece design is now the only version of the upper control
arm available for service of prior model year Rangers.
ACTION Use the following Camber And Caster Adjustment procedure when either camber or
caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a
vehicle equipped with single piece upper control arm.
Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if
only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm.
SERVICE PROCEDURE
CAMBER AND CASTER ADJUSTMENT
NOTE
THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST
BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME
SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE
MOVEMENT OF THE UPPER ARM IN THE SLOT.
1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1).
2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is
tension, but the upper control arm can be moved for the alignment adjustment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Alignment Procedure Revision > Page 2261
3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and
rear of the upper control arm should be made equally.
4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m).
5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for
information.
CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM
1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the
ball joint forward.
2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint
rearward.
3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m).
4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for
information.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3084 07
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2262
Alignment: Specifications
Alignment Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2263
General Specifications
Related Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2264
Alignment: Description and Operation
WHEEL ALIGNMENT ANGLES
Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting
bolts. Toe is adjusted by the use of the front wheel spindle tie-rod.
Negative and Positive Camber
Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive
or negative and has a direct effect on tire wear.
Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when
viewed from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Positive Toe (Toe In)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2265
Negative Toe (Toe Out)
Toe The vehicle toe setting: ^
affects tire wear and directional stability.
^ must be checked after adding aftermarket equipment, such as a snowplow or body.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2266
Ride Height
Wheel Track
Wheel Track
Dogtracking
Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily
crowned roads can give the illusion of dogtracking.
Wander Wander is the tendency of the vehicle to require frequent, random left and right steering
wheel corrections to maintain a straight path down a level road.
Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the
steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually
experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes
or irregularities in the road surface.
Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with
various road surfaces and observed by the driver as small rotational oscillations of the steering
wheel.
Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor
return of the steering wheel to center after a turn or the steering correction is completed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2267
Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be
overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does
with hands off the steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the
steering wheel as the wheel is rocked slowly left and right within very small turns around center or
straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center."
^
Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear
teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the
effort from the self-aligning forces at the road wheel or tire patch.
^ In the diagnosis of a readability problem, it is important to understand the difference between
wander and poor groove feel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment
Alignment: Service and Repair Camber and Caster Adjustment
Camber and Caster Adjustment
1. Remove the nuts and alignment plates.
2. Install the cams and the nuts.
3. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame
pocket to aid in moving the arm.
To increase the LF caster and camber, use the following steps. 1
To increase caster, move the front of the front suspension arm bushing joint outboard and move
the rear of the front suspension arm bushing joint inboard.
2 To increase camber, move the front suspension arm bushing joint outboard equally.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2270
4. To decrease the LF caster and camber, use the following steps.
1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move
the rear of the front suspension arm bushing joint outboard.
2 To decrease camber, move the front suspension arm bushing joint inboard equally.
5. Tighten the nuts.
6. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame
pocket to aid in moving the arm.
To increase RF caster and camber, use the following steps. 1
To increase caster, move the front of the front suspension arm bushing joint outboard and move
the rear of the front suspension arm bushing joint inboard.
2 To increase camber, move the front suspension arm bushing joint outboard equally.
7. To decrease the RF caster and camber, use the following steps.
1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move
the rear of the front suspension arm bushing joint outboard.
2 To decrease camber, move the front suspension arm bushing joint inboard equally.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2271
8. Increase the caster split.
1 Loosen the nuts.
2 Adjust the caster set bolts forward.
9. Decrease the caster split.
1 Loosen the nuts.
2 Adjust the caster set bolts rearward.
10. Tighten the nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2272
Alignment: Service and Repair Ride Height
Ride Height
1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to
normalize the vehicle static ride height.
3. Measure the distance between the center line of the front suspension lower arm bushing bolt
and the lift. Record the measurement.
4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the
measurement.
^ Take the measurement from the midpoint of the surface shown.
5. Determine ride height.
^ Subtract measurement 1 from measurement 2. This is the ride height.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2273
6. NOTE: The torsion bar adjusting bolt is coated with adhesive that wears off after disassembly. If
the torsion bar system is ever disassembled or
the torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when
re-assembling.
Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting
bolt. ^
Tighten the torsion bar adjusting bolt to increase the torque or raise the height.
^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2274
Alignment: Service and Repair Toe Adjustment
Toe Adjustment
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake
pedal.
3. Check the toe settings; follow the manufacturer's instructions.
4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is
rotated.
Remove the clamps.
5. Loosen the nuts.
^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2275
6. Rotate the front wheel spindle tie-rods.
7. Tighten the nuts.
8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information > Page 2282
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 2283
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 2284
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the fuel injection supply manifold.
2. Remove the two bolts, the pressure relief valve and the O-ring seals.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications > With Flexible Fuel
Idle Speed: Specifications With Flexible Fuel
With Automatic Transmission
Hot Idle ................................................................................................................................................
......................................................... 800 - 900 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
......................................................... 800 - 900 RPM
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications > With Flexible Fuel > Page 2289
Idle Speed: Specifications Without Flexible Fuel
With Automatic Transmission
Hot Idle ................................................................................................................................................
......................................................... 760 - 880 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
......................................................... 760 - 880 RPM
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the lower air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 2297
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Disconnect the battery ground cable.
2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure.
This may drain fuel from the system. Drain the fuel
into a suitable container.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 2298
Fuel Pressure Gauge
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Coil Terminal-To-Cylinder Relationship
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications > Page 2302
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions
Ignition Cable: Service Precautions
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions > Page 2310
Ignition Cable: Service and Repair
Spark Plug Wire Remover
SPECIAL TOOL(S)
REMOVAL
1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug.
CAUTION: ^
Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the
ignition coil. 3. Disconnect the spark plug wires from the separators and remove the spark plug
wires.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the
exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of
the spark plug wire.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions > Page 2311
Spark Plug Wire Remover
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Spark Plug Gap
Spark Plug: Specifications Spark Plug Gap
Spark Plug Gap ...................................................................................................................................
.................................... 1.3-1.4 mm (0.052-0.056 in.)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Spark Plug Gap > Page 2316
Spark Plug: Specifications Spark Plug Torque
Spark Plug Torque ...............................................................................................................................
...................................................... 20 Nm (15 ft lbs)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2317
Spark Plug: Application and ID
RH Original Spark Plug .......................................................................................................................
.............................................................. AGRF22PG LH Original Spark Plug .....................................
...................................................................................................................................................
AGRF22P New Spark Plug (Either Side) ............................................................................................
................................................................................. AGSF22PP
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2318
Spark Plug: Service and Repair
REMOVAL
1. Remove the spark plug wires from the spark plugs.
2. Remove the spark plugs.
NOTE: ^
Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from.
New spark plugs can be used in any cylinder.
3. Inspect the spark plugs.
4. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2322
Compression Check: Testing and Inspection
Compression Test General Remarks
NOTE: Removing fuses and disconnecting electrical components causes the powertrain control
module (PCM) to log an error message. After the measurements have been carried out this error
message should be cleared from memory by connecting to PDU.
NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this
can be adjusted).
The compression pressure should be checked with the engine at operating temperature.
Check The Compression Pressure
WARNING: On manual transmissions shift the transmission into neutral. On automatic
transmission vehicles, select "P". Failure to follow these instructions may result in personal injury.
1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds
then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter
switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank
the engine a
minimum of five compression strokes and record the highest reading. Note the approximate
number of compression strokes required to obtain the highest reading.
6. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes. 7. Install the components in reverse order, observing the specified tightening
torques. 8. Reset the PCM fault memory.
Interpretation of the Results
The indicated compression pressure are considered within specification if the lowest reading
cylinder is within 75% of the highest reading.
CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the
measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent
damage to the catalytic converter.
If the measurement on one or more cylinders is much lower than the specified value, spray some
engine oil into the combustion chamber and repeat the compression measurement. If the reading
greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either
damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other
are both too low then it is very likely that the cylinder head gasket between them is burnt through.
This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does
not require adjustment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 2329
Drive Belt: Service and Repair
Accessory Drive Belt
Removal and Installation
1. Remove the air cleaner outlet tube.
2. Remove the accessory drive belt.
1 Rotate the accessory drive belt tensioner counterclockwise.
2 Remove the belt.
3. NOTE: Refer to Component Locations for correct drive belt routing.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the lower air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service
Precautions
Evaporative Canister Filter: Service Precautions
WARNING:
^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED
FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE
DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM
THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING,
POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE
PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service
Precautions > Page 2340
Evaporative Canister Filter: Service and Repair
REMOVAL
1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
3. Disconnect the two chassis emissions lines from the evaporative emission tube.
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
4. Remove the evaporative emissions canister bolts.
5. Remove the evaporative emission canister with bracket assembly.
1 Disconnect the canister vent solenoid electrical connector.
2 Remove the EVAP canister with bracket assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service
Precautions > Page 2341
6. Disconnect the canister vent solenoid hose assembly.
7. Remove the evaporative emission dust separator.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emission system. See: Powertrain Management/Emission Control
Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
Repair Verification Drive Cycle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications
Fluid Filter - A/T: Specifications
Transmission Fluid Filter Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2345
Fluid Filter - A/T: Service and Repair
Fluid Pan, Gasket and Filter
Removal
1. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to
drain. After fluid is drained, remove the front two transmission fluid pan screws.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2346
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid
XT-5-QM meeting Ford specification MERCON
(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter.
^
Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2347
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the
vehicle.
8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
Fill transmission to the correct fluid level and check for correct transmission operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2348
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification
MERCON(R) V.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions > Page 2353
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Disconnect the battery ground cable.
2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure.
This may drain fuel from the system. Drain the fuel
into a suitable container.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions > Page 2354
Fuel Pressure Gauge
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2364
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2365
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
2371
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
2372
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation
Hose/Line HVAC: Description and Operation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C
evaporator core orifice.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation
> Page 2376
Hose/Line HVAC: Service and Repair
REMOVAL
1. Prepare the vehicle for condenser to evaporator tube removal.
1 Disconnect the battery ground cable.
2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant.
3 Remove the air cleaner assembly.
2. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard
the O-ring seal.
- During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification
WSH-M1C231-B.
3. Disconnect and remove the condenser to evaporator tube.
INSTALLATION
1. To install, reverse the removal procedure. 2. Evacuate, leak test, and charge the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation
> Page 2377
Disconnect Tool Set, Spring Lock Coupling
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications
Power Steering Line/Hose: Specifications
Steering line to gear clamp plate nut 18 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications >
Page 2381
Power Steering Line/Hose: Service and Repair
Hose
Special Tools
Special Tool(s)
Removal and Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications >
Page 2382
1. Refer to the System View illustration for the hose routing and retention points.
2. When connecting a fitting with a seal ring, a new seal ring must be installed.
^ The special tool is used to install the return line connector seal and the pressure line connector
seal.
3. Fill, purge and leak check the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
Brake Fluid High Performance DOT 3
Dot 4 may be used if Dot 3 is not available.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 2387
Brake Fluid: Description and Operation
Brake Fluid
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or
equivalent meeting Ford specification ESA-M6C25A. ^
Do not reuse brake fluid drained or bled from the system.
^ Do not use brake fluid that has been stored in an open container.
^ Do not use contaminated brake fluid.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications
Clutch Fluid: Specifications
Ford High Performance DOT3 Motor Vehicle Brake Fluid C6AZ-19542-AB ESA-M6C25-A, DOT3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine Coolant - Propylene Glycol Recommendations
Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations
Article No. 01-23-6
11/26/01
^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON
ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL
^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION
ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS
FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002
CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR
2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO
1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002
EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F
SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER
SPORT 2000-2002 F-650, F-750
LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD
MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE
1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002
VILLAGER 1997-2002 MOUNTAINEER
MERKUR: 1989 SCORPIO, XR4TI
This article is being republished in its entirety to update the model year coverage.
ISSUE This TSB article describes Ford Motor Company's position on the use of propylene
glycol-based engine coolants.
ACTION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine Coolant - Propylene Glycol Recommendations > Page 2395
Ford Motor Company does not recommend nor endorse the use of engine coolants made with
propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene
glycol-based engine coolants.
Published information suggests that engine coolants made with propylene glycol may provide
engine cooling performance equivalent to engine coolants made with ethylene glycol. However,
different brands of engine coolant provide varying corrosion protection for the cooling system. Ford
does not have performance data for the multitude of engine coolants available in the aftermarket
and therefore cannot recommend the use of any coolant except those sold by Ford Customer
Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer
Service Division coolant for the vehicle.
Furthermore, claims of toxicological and environmental advantages of propylene glycol over
ethylene glycol may be misleading. When significant new information is developed, Ford will review
this policy.
Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene
glycol-based engine coolants. Those specifications do not refer to engine coolants made with
propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon
the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its
components, the cost of repairing the damage would not be covered by the Ford New Vehicle
Limited Warranty.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 402000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum
and Temperature Specifications
Coolant: Pressure, Vacuum and Temperature Specifications
Pressure Test
Cooling System ...................................................................................................................................
...................................................................... 20 psi
Thermostat Opening Temperature
Starts To Open ....................................................................................................................................
................................................ 183 - 190 degrees F Fully Open .........................................................
.......................................................................................................................................... 210
degrees F
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum
and Temperature Specifications > Page 2398
Coolant: Capacity Specifications
Cooling System Capacity 14.0 qt (US)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum
and Temperature Specifications > Page 2399
Coolant: Fluid Type Specifications
Antifreeze Type Ford Premium Engine Coolant (Green in color)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid ..............................................................................................................................
..................................................................... 10.0 qts Note: Approximately Dry Fill Capacity
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 2404
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
Type .....................................................................................................................................................
............................................................. MERCON V
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid
Level Check and Condition, Change
Fluid - A/T: Service and Repair A/T Fluid Level Check and Condition, Change
Fluid Pan, Gasket and Filter
Removal
1. Raise and support the vehicle.
NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail
and positioned out of the way for fluid pan removal.
If equipped, loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
- Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove
the converter.
- Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to
drain. After fluid is drained, remove the front two transmission fluid pan screws.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid
Level Check and Condition, Change > Page 2407
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid
XT-5-QM meeting Ford specification MERCON
(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter.
^
Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid
Level Check and Condition, Change > Page 2408
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the
vehicle.
8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
Fill transmission to the correct fluid level and check for correct transmission operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid
Level Check and Condition, Change > Page 2409
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification
MERCON(R) V.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid
Level Check and Condition, Change > Page 2410
Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug
Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug
Draining
CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission
fluid additives, treatments or cleaning agents. The use of these materials can affect the operation
of the transmission, resulting in internal component failure.
1. With the vehicle in PARK, position on a hoist.
2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail
and positioned aside for fluid pan removal.
If equipped, loosen the nut and position the heat shield aside.
3. Place a drain pan under the transmission fluid pan.
4. Drain the transmission fluid.
^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to
drain. After the fluid is drained, remove the front two transmission fluid pan screws.
5. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid
Level Check and Condition, Change > Page 2411
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces.
Refill
1. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan
^ Loosely install the transmission fluid pan screws.
2. Tighten the transmission fluid pan screws.
^ Tighten the transmission fluid pan screws in a crisscross sequence.
3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the
vehicle.
5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
With the engine running and the transmission at normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is
needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should
be in the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid
Level Check and Condition, Change > Page 2412
cross-hatched area of the fluid level indicator).
6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the
gears. 8. Check the transmission fluid level.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid
Level Check and Condition, Change > Page 2413
Fluid - A/T: Service and Repair Automated Equipment
Transmission Fluid Drain and Refill-Automated Equipment
Special Tool(s)
Draining
CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission
fluid additives, treatments or cleaning agents. The use of these materials can affect the operation
of the transmission, resulting in internal component failure.
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: This is a new procedure for draining and adding transmission fluid using a suitable
transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a
suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine,
connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will
help remove any foreign material trapped in the fluid coolers.
4. Carry out the fluid exchange process.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the
vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission fluid level
and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the
correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
M/T - Mercon(R) V ATF Usage Information
Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information
TSB 06-26-1
01/08/07
MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME
MANUAL TRANSMISSIONS
FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco
1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super
Duty 2001-2003 Explorer Sport Trac, Explorer Sport
LINCOLN: 2001-2002 Lincoln LS
MERCURY: 1984-1995 Cougar 1987-1999 Tracer
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the
service fluid for manual transmissions originally requiring MERCON(R).
ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can
now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual
usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic
Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue
until remaining inventory has been depleted.
SERVICE PROCEDURE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
M/T - Mercon(R) V ATF Usage Information > Page 2418
Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper
fluid application on current and past model manual transmissions refer to the fluid usage chart.
(Figure 1)
WARNING
FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR
OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT
(XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS
RECOMMENDING THAT PARTICULAR FLUID.
USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
M/T - Mercon(R) V ATF Usage Information > Page 2419
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Specifications
Fluid - M/T: Capacity Specifications
Manual Transmission
Capacity ...............................................................................................................................................
................................................................... 2.7 Quarts Note: Approximate refill. Service refill
capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a
level surface.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Specifications > Page 2422
Fluid - M/T: Fluid Type Specifications
Manual Transmission Fluid ..................................................................................................................
............................................................. Mercon ATF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
Refill .....................................................................................................................................................
............................................................. 5.5-5.8 pints
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 2427
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Conventional ........................................................................................................................................
..................................................................... 80W-90 Traction-Lok .....................................................
...................................................................................................................................... 75W-140
Synthetic
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications
Technical Service Bulletin # 02-1-9 Date: 020121
Engine Oil - Oil Recommendations/Applications
Article No. 02-1-9
01/21/02
ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30
MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY
FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002
ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002
FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER
1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002
LS 1998-2002 NAVIGATOR
MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999
TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001
MOUNTAINEER
This article is being republished in its entirety to update the vehicle models, engines and years
affected.
NOTE
PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A
COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB.
ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most
gasoline and flexible fueled vehicles.
ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the
recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to
improve fuel economy.
Testing has validated this viscosity grade can be used in many previous model year vehicles. It is
recommended ALL vehicles on the following Vehicle Application Listing be service with SAE
5W-20.
All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002
Vehicles" chart are being filled with SAE 5W-20
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 2432
motor oil at the factory and should also be serviced with SAE 5W-20 oil.
Exception 2001 Vehicles
Exception 2002 Vehicles
NOTE
IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED.
REFER TO TSB 99-8-16.
Parts Block
OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000
Veh. App. Listing Approved For SAE 5W-20 Motor Oil
^ 1993-1996 1.9L Escort/Tracer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 2433
^ 1995-2000 2.0L Zetec Contour/Mystique
^ 1999-2002 2.0L Cougar
^ 1997-2002 2.0L Escort/Tracer
^ 1998-2002 2.0L Escort ZX2
^ 2000-2002 2.0L Focus
^ 2001-2002 2.0L Escape
^ 1993-1997 2.3L Ranger
^ 1993-1994 2.3L Mustang
^ 1993-1994 2.3L Tempo/Topaz
^ 1998-2001 2.5L Ranger
^ 1995-2000 2.5L Contour/Mystique
^ 1999-2002 2.5L Cougar
^ 2001-2002 3.0L 4V Escape
^ 1996-2001 3.0L 4V Taurus/Sable
^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger,
^ Taurus/Sable (Flexible Fuel and Gas)
^ 1995-2000 3.0L (Vulcan) Windstar
^ 1993-1994 3.0L (Vulcan) Tempo/Topaz
^ 2000-2002 3.0L 4V Lincoln LS
^ 1995-2002 3.8L Windstar
^ 1993-1997 3.8L Taurus/Sable,
^ Thunderbird/Cougar, Continental
^ 1994-2002 3.8L Mustang
^ 2002-2002 3.9L 4V Lincoln LS
^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series
^ 1996-2002 4.6L 2V Mustang
^ 1992-2002 4.6L Crown Victoria/Grand Marquis
^ 1991-2002 4.6L Town Car
^ 1994-1997 4.6L 2V Thunderbird/Cougar
^ 1996-2002 4.6L 4V Mustang Cobra
^ 1995-2002 4.6L 4V Continental
^ 1993-1998 4.6L 4V Mark VIII
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 2434
^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition
^ 1993-1999 4.9L E-Series, F-Series
^ 1993-1995 5.0L Mustang/Mustang Cobra
^ 1993-1993 5.0L Thunderbird/Cougar
^ 1997-2001 5.0L Explorer/Mountaineer
^ 1993-1996 5.0L E-Series, F-Series, Bronco
^ 2000-2002 5.4L Excursion
^ 1998-2002 5.4L 2V/4V Navigator
^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350
Chassis/RV/Cutaway
^ 1993-1997 5.8L F-Series, Bronco
^ 1993-1996 5.8L E-Series
^ 2000-2002 6.8L Excursion
^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway
^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome
^ 1993-1998 7.5L All Vehicles
NOTE
FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV.
NOTE
THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR
OIL
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure,
Vacuum and Temperature Specifications
Engine Oil: Pressure, Vacuum and Temperature Specifications
General Specifications
Oil Pressure At 2,000 Rpm ..................................................................................................................
................................................................. 40 - 60 psi
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure,
Vacuum and Temperature Specifications > Page 2437
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................
............................................................. 4.7L (5.0 Qt)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure,
Vacuum and Temperature Specifications > Page 2438
Engine Oil: Fluid Type Specifications
Engine Oil Type ...................................................................................................................................
............................................... SAE 5W-30 Motor Oil
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Mercon V(R) Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage
TSB 07-1-7
01/22/07
MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER
STEERING SYSTEMS
FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort
2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle
2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53
Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005
Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007
Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series
2000-2007 F-650, F-750 2006-2007 Low Cab Forward
LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln
LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator
2006-2007 Mark LT 2007 MKX
MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar
2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002
Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid for power steering systems originally requiring MERCON(R).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2443
ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be
serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids
labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission
Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining
inventory has been depleted.
SERVICE PROCEDURE
Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V.
CAUTION
APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER
STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY
OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Page 2444
Power Steering Fluid: Specifications /
/
Power Steering Fluid Type MERCON(R) ATF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Capacity ...............................................................................................................................................
......................................................... 0.85 kg (30 oz)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 2449
Refrigerant: Fluid Type Specifications
A/C Refrigerant ....................................................................................................................................
....................................... R-134a Refrigerant YN-19
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer
Safety Information
Refrigerant: Customer Safety Information
WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT
POSSIBLE PERSONAL INJURY
.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer
Safety Information > Page 2452
Refrigerant: Environmental Impact Information
The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a
protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun.
Ozone Depletion Scientific research performed over the past 15 years links the release of
chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone
depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer
located in the stratosphere where they react with and destroy ozone molecules.
Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown
to lead to higher incidents of cancer as well as global warming. When viewed from a global
perspective, ozone depletion holds an enormous potential for damage.
Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of
the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial
but the same compound, when located at ground level, is harmful to humans, animals, crops and
vegetation.
Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with
nitrogen oxides (NOx) in the presence of sunlight and heat.
Montreal Protocol In response to the growing body of evidence demonstrating the detrimental
effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to
establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become
signatories to this agreement leading to an end of production of R12 in December, 1995, in all
developed countries.
As established by the Montreal Protocol, R12 production in developed countries has ceased.
Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned
production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to
control both the production and use of (CFC)s for refrigerant applications including mobile vehicle
air conditioning systems.
Additional Information Sources
For more complete and detailed explanations of the above policies, please refer to:
http://www.epa.gov/ozone/
Technician Certification Organizations providing technician refrigerant recovery and recycling
certification include:
National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2
Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/
International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX
76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/
Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041
Phone: 215-679-2220
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer
Safety Information > Page 2453
Fax: 215-541-4635 http://www.macsw.org/
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer
Safety Information > Page 2454
Refrigerant: Technician Safety Information
WARNING:
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE AIR BAG SYSTEM
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING ANY CLIMATE
CONTROL COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY, DISCONNECT THE
BATTERY GROUND CABLE AND WAIT ONE MINUTE.
CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY
TO OPERATE THE ENGINE WITH VEHICLE IN A CLOSED AREA SUCH AS A GARAGE,
ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE
CLOSED AREA.
R-134A IS CLASSIFIED AS A SAFE REFRIGERANT, BUT MISUSE CAN MAKE IT
DANGEROUS. THE FOLLOWING PRECAUTIONS MUST BE OBSERVED. ALWAYS WEAR SAFETY GOGGLES WHEN REPAIRING AN AIR CONDITIONING SYSTEM.
- AVOID CONTACT WITH LIQUID REFRIGERANT R-134A. R-134A VAPORIZES AT
APPROXIMATELY -25°C (-13°F) UNDER ATMOSPHERIC PRESSURE AND IT WILL FREEZE
SKIN TISSUE.
- NEVER ALLOW REFRIGERANT R-134A GAS TO ESCAPE IN QUANTITY IN AN OCCUPIED
SPACE. R-134A IS NON-TOXIC, BUT IT WILL DISPLACE THE OXYGEN NEEDED TO
SUPPORT LIFE.
- NEVER USE A TORCH IN AN ATMOSPHERE CONTAINING R-134A GAS. R-134A IS
NON-TOXIC AT ALL NORMAL CONDITIONS, BUT WHEN IT IS EXPOSED TO HIGH
TEMPERATURES, SUCH AS A TORCH FLAME, IT DECOMPOSES. ONE OF THE PRODUCTS
OF THE CHEMICAL BREAKDOWN IS A PHOSGENE GAS, WHICH IS HIGHLY TOXIC.
- DO NOT ALLOW ANY PORTION OF THE CHARGED AIR CONDITIONING SYSTEM TO
BECOME TOO HOT. THE PRESSURE IN AN AIR CONDITIONING SYSTEM RISES AS THE
TEMPERATURE RISES AND TEMPERATURES OF APPROXIMATELY 85°C (185°F) CAN BE
DANGEROUS.
- ALLOW THE ENGINE TO COOL SUFFICIENTLY PRIOR TO PERFORMING MAINTENANCE
OR SERIOUS BURNS AND INJURY CAN OCCUR.
DUE TO REFRIGERANT HAZARDS, ALWAYS WEAR SAFETY GOGGLES AND
NON-PENETRABLE GLOVES WHEN WORKING ON OR FLUSHING A/C SYSTEMS.
USE EXTREME CARE AND OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS RELATED
TO THE USE OF REFRIGERANTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer
Safety Information > Page 2455
Refrigerant: Vehicle Damage Warnings
CAUTION:
To avoid damaging the vehicle or A/C components, the following precautions must be observed. The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging.
Failure to due so can contaminate the shop bulk refrigerant and other vehicles.
- Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These
two types of refrigerant must never be mixed. Doing so can damage the A/C system.
- Charge the A/C system with the engine running only at the low-pressure side to prevent
refrigerant slugging from damaging the A/C compressor.
- Use only R-134a refrigerant. Due to environmental concerns, when the air conditioning system is
drained, the refrigerant must be collected using refrigerant recovery/recycling equipment. Federal
law REQUIRES that R-134a be recovered into appropriate recovery equipment and the process be
conducted by qualified technicians who have been certified by an approved organization, such as
MACS, ASI, etc. Use of a recovery machine dedicated to R-134a is necessary to reduce the
possibility of oil and refrigerant incompatibility concerns. Refer to the instructions provided by the
equipment manufacturer when removing refrigerant from or charging the air conditioning system.
- Refrigerant R-134a must not be mixed with air for leak testing or used with air for any other
purpose above atmospheric pressure. R-134a is combustible When mixed with high concentrations
of air and higher pressures.
- A number of manufacturers are producing refrigerant products that are described as direct
substitutes for Refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely
damage the A/C components. If repair is required, use only new or recycled Refrigerant R-134a.
- Use a back-up wrench to prevent damage to the tubes.
To avoid contamination of the A/C system: Never open or loosen a connection recovering the refrigerant using approved equipment.
- When loosening a connection, if any residual pressure is evident, allow it to leak out before
opening the fitting.
- Perform the Refrigerant Discharging and Recovery Procedure on a system that has been opened
to install a new component or one that has discharged through leakage before charging.
- Seal open fittings with a cap or plug immediately after disconnecting a component from the
system.
- Clean the outside of the fittings thoroughly before disconnecting a component from the system.
- Do not remove the sealing caps from a new component until ready to install.
- Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil
container until ready to use, and install the cap immediately after using. Store the oil in a clean,
moisture-free container.
- Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal with
refrigerant oil before connecting.
- When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or
any sharp edges that can chafe the line.
- Tighten threaded fittings only to specifications. The steel and aluminum fittings used in the
refrigerant system will not tolerate overtightening.
- When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the
refrigerant lines or tubes.
- Do not open a refrigerant system or uncap a new component unless it is as close as possible to
room temperature. This will prevent condensation from forming inside a component that is cooler
than the surrounding air.
- Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If
the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all
the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other
cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful
in removing small traces of contamination from the air that might affect the leak detector.
- During normal A/C operation, oil is circulated through the system with the refrigerant, and a small
amount is retained in each component. If certain components of the system are removed for new
installation, some of the refrigerant oil will go with the component. To maintain the original total oil
charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part.
- If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12
recovery/recycling equipment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure
Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure
Special Tool(s)
SPECIAL TOOL(S)
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
Refrigerant System Recovery
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. 2. Connect
an R-134a A/C service center to the low- and high-pressure service gauge port valves.
NOTE: Some R-134a service centers require the use of an A/C manifold gauge set.
3. Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant from the
system following the operating instructions
provided by the equipment manufacturer.
4. Once the service center has recovered the vehicle A/C system refrigerant, close the service
center inlet valve (if equipped). Then switch off the
power supply.
5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system
vacuum level on the gauge. If the vacuum does not
decrease, disconnect the refrigerant center hose(s).
6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains
stable for two minutes. 7. Carry out the required repairs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2458
Refrigerant: Service and Repair Identifying Refrigerants
Delux A/C Refrigerant Analyzer
SPECIAL TOOL(S)
1. Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the sample
for testing.
NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the
refrigeration system or storage containers prior to recovering or charging the refrigerant system.
2. The diagnostic tool will display one of the following:
- If the purity level of R-134a or R-12 is 98% or greater by weight, the green "PASS" light emitting
diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will
be displayed on the digital display.
- If refrigerants R-134a or R-12 do not meet the 98% purity levels, the red "FAIL" LED will light and
a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12,
R-22, and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light,
"Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting the user
of potential hazards. The weight concentrations of R-134a, R-12, R-22,and hydrocarbons will also
be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a or R-12 content is
98% or greater. The diagnostic tool eliminates the
effect of air when determining the refrigerant sample content because air is not considered a
contaminant, although air can affect A/C system performance. When the diagnostic tool has
determined that a refrigerant source is pure (R-134a or R-12 is 98% or greater by weight) and air
concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air
purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated. 5. Perform the Refrigerant Discharging and Recovery
Procedure to remove any contaminated refrigerant using suitable recovery-only equipment
designed for capturing and storing contaminated refrigerant.
CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or
R-12 recovery/recycling equipment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2459
Refrigerant: Service and Repair Handling of Contaminated Refrigerants
1. Perform the Refrigerant Discharging and Recovery Procedure to remove the contaminated
refrigerant using suitable recovery-only equipment
designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to
other vehicles.
- If this equipment is not available, contact an A/C repair facility in your area with the correct
equipment to carry out this repair.
CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your
recovery/recycling equipment.
2. Determine and correct the cause of the customer's initial concern. 3. The suction
accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed.
Remove the suction accumulator/drier.
NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured for
correct oil system matching. See: Refrigerant Oil Addition.
4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction
accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8.
Dispose of contaminated refrigerant according to all federal, state and local regulations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2460
Refrigerant: Service and Repair Evacuation and Charging
Special Tool(s)
SPECIAL TOOL(S)
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
Refrigerant System Evacuation
1. Connect an R-134a service center to the low- and high-pressure service gauge port valves. 2.
Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum
and as close to 101.1 kPa (30 in-Hg) as
possible. Continue to operate the vacuum pump for a minimum of 45 minutes.
3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that
the system vacuum is held. If vacuum is not held
for five minutes, leak test the system, service the leak, and evacuate the system again.
Refrigerant System Charging
1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the
system. See: Refrigerant Oil Addition. 2. Charge the system with the specified amounts of
refrigerant oil and refrigerant. 3. When no more refrigerant is being drawn into the system, start the
engine and select MAX A/C operation. Adjust the blower motor speed to the
maximum and allow the remaining refrigerant to be drawn into the system. Continue to add
refrigerant into the system until the specified weight of R-134a has been added. Close the charging
cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the
low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2461
Refrigerant: Service and Repair Leak Detection
Electronic Leak Detection
Refrigerent Leak Detector
SPECIAL TOOL(S)
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be
carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate
this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake
cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated
area, is very helpful in removing small traces of contamination from the air that might affect the leak
detector.
1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and
operation techniques.
NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
2. If a leak is found, Perform the Refrigerant Discharging and Recovery Procedure to remove the
refrigerant.
- Repair the system.
- Test the system for normal operation.
Tracer Dye Leak Detection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2462
120 Watt 110 Volt UV Lamp 20 Degree Celsius
SPECIAL TOOL(S)
NOTE: Ford Motor Company vehicles are produced with a permanent leak tracer dye incorporated
into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the
tracer dye. Since more than one leak can exist, always inspect each component.
1. Check for leaks using a 120 Watt UV spot lamp.
- Scan all components, fittings and lines of the A/C system.
2. After the leak is repaired, remove any traces of tracer dye with a general purpose oil solvent.
3. Verify the repair by operating the system for a short time and inspect with the UV spot lamp.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Capacity ...............................................................................................................................................
............................................................ 266 ml (9 oz)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 2467
Refrigerant Oil: Fluid Type Specifications
PAG Refrigerant Compressor Oil
R-134a Systems ...................................................................................................................
F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2468
Refrigerant Oil: Service Precautions
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed for new installation, some of the refrigerant oil will go with the component. To maintain the
original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system
with the new part.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2469
Refrigerant Oil: Service and Repair
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed for new installation, some of the refrigerant oil will go with the component. To maintain the
original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system
with the new part.
1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour
the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a
Systems) or equivalent into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5
ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a
Systems) or equivalent into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces),
pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent
into the new A/C compressor.
NOTE: Service A/C compressors are shipped without compressor oil.
2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier
cylinder and drain the oil into a calibrated container.
- Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml
(2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil
(R-134a Systems) or equivalent to the suction
accumulator/drier inlet tube.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2470
4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil
(R-134a Systems) or equivalent to the A/C condenser
core or the suction accumulator/drier inlet tube.
5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent
to the suction accumulator/drier inlet tube when
carrying out each of the following repairs: installation of a new A/C evaporator core orifice
- installation of a new A/C compressor pressure relief valve
- installation of a new refrigerant line
- repair of an O-ring seal leak
- repair of a charge port leak
6. Installation of new components that do not require you to Perform the Refrigerant Discharging
and Recovery Procedure of refrigerant and
resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require
additional oil.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications
Brake Bleeding: Specifications
Disc brake caliper bleeder screw 15 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding
Brake Bleeding: Service and Repair Brake Caliper Bleeding
Caliper
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2476
Brake Bleeding: Service and Repair Brake System Manual Bleeding
Manual
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Disc brake is shown, drum brake is similar.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the tube in a container partially filled with clean brake
fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2477
4. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw, ending with the LH front bleeder
screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2478
Brake Bleeding: Service and Repair Brake System Pressure Bleeding
Pressure
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Disc brake is shown, drum brake is similar.
NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2479
5. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front bleeder screw, ending with the LH front
bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2480
Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU)
Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU)
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
NOTE: This procedure only needs to be carried out if a new 4-wheel anti-lock brake (4WABS)
hydraulic control unit (HCU) has been installed.
1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash, and follow the scan tool instructions for
bleeding.
2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
3. NOTE: Disc brake is shown, drum brake is similar.
Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially
filled with recommended brake fluid.
4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2481
5. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw, ending with the LH front bleeder
screw.
7. Repeat the bleed procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2482
Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench
Master Cylinder Priming-In-Vehicle or Bench
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake component and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air
can get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When a new brake master cylinder has been installed or the system has been emptied or
partially emptied, it must be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder.
2. For bench priming, mount the brake master cylinder in a vise.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2483
3. Install short brake tubes with the ends bent into the brake master cylinder reservoir.
^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.
4. For a new brake master cylinder, loosen the speed control pressure switch. 5. Slowly depress
and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the
brake pedal.
6. Tighten the speed control pressure switch. 7. Repeat the above three steps until no air bubbles
are visible in the expelled fluid. 8. Slowly depress the primary piston or, for in-vehicle priming, have
an assistant slowly pump the brake pedal until clear brake fluid flows from both
brake tubes with no air bubbles.
9. If necessary, install the brake master cylinder into the vehicle.
10. Remove the short brake tubes and install the master cylinder outlet tubes.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2484
11. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU).
12. NOTE: Refill the brake master cylinder reservoir as necessary.
Have an assistant depress and hold the brake pedal.
13. Tighten the outlet tube fitting at the HCU. 14. Repeat the above three steps until no air bubbles
are visible in the expelled brake fluid.
15. Repeat the above four steps for the remaining master cylinder outlet tube.
16. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other
end in a container partially filled with the specified
brake fluid.
17. Have an assistant pump and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2485
18. NOTE: Refill the brake master cylinder reservoir as necessary.
Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube.
19. Tighten the master cylinder bleeder screw. 20. Repeat the above three steps until there are no
air bubbles in the expelled brake fluid. 21. Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 2486
Brake Bleeding: Tools and Equipment
Special Tools
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Seats Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Disconnect the battery ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical
connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air
bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor
connector.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side floor connector. 11. Reconnect the battery ground cable.
Seats Not Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery
ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2491
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate
controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint
system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector
to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector
beneath the front seat.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
passenger side air bag electrical connector beneath
the front seat.
11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat.
12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side air bag electrical connector beneath the
front seat.
13. Reconnect the battery ground cable.
Deactivation Procedure
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will This will
reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2492
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood connected.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2493
8. Remove the driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
11. Open the glove compartment door past its stops to access the mounting screws.
12. Remove the two screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2494
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door. Reaching one hand into the glove
compartment opening push out on the passenger air bag module and separate it from the
instrument panel. Note the wire harness routing for installation.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
Vehicles without seat side air bags
16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag
bridge resistor from the side air bag to floor connector.
If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints
control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor
connector, a low resistance fault will be generated by the RCM.
Vehicles with seat side air bags and power driver seat
17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the battery ground
cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Vehicles with seat side air bags
18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side
air bags and power driver seat
19. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery
ground cable (14301) and wait at least one minute. For additional information, See: Starting and
Charging/Battery
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Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2495
Vehicles with seat side air bags
20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
All vehicles
24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close
the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery
Reactivation Procedure
Reactivation
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2496
1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the
instrument panel, open the kick panel cover and remove the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the wiring Diagram Manual.
3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
Vehicles with seat side air bags
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
Vehicles with seat side air bags and power driver seat
8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2497
Vehicles with seat side air bags
9. Position the front seats rearward.
Vehicles with seat side air bags and power driver seat
10. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air
bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply
energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery
All vehicles
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical
connector.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Position the passenger air bag module into the instrument panel. Route the wire harness as noted
in removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2498
14. Install the two screws.
15. Close the glove compartment door.
16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
17. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to
the steering wheel.
18. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2499
19. Install the two steering wheel back cover plugs.
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear
blower, 15A with rear blower) to the CJB and close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to
OFF. Wait 10 seconds, then turn the key back to
ON and visually monitor the air bag indicator with the air bag modules installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an air bag
supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light.
-remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after
the ignition switch has been turned from the OFF to the ON position. This is the time required for
the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is
inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this
occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
25. Clear all continuous DTCs from the restraints control module using a scan tool.
Procedures For Repair Operations
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2500
accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2501
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2502
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2503
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2504
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Seats Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic
tool from the driver seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger
seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic
tool from the clockspring connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2505
8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable.
10. Prove out the system.
Seats Not Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring
connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove
the restraint system diagnostic tool from the floor connector beneath the front passenger seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the
passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from
the floor connector beneath the driver seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver
seat.
10. Reconnect the battery ground cable. 11. Prove out the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2506
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2507
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint
System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2513
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2514
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2515
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2516
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2517
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2518
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2519
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2520
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2521
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2522
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2523
Fuse: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2524
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2525
Fuse: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2526
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2527
Fuse: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2528
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2531
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2532
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2533
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2534
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2535
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2536
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2537
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2538
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2539
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2540
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2541
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2542
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2543
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2544
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2545
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2546
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2547
Fuse: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2548
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2549
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2552
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2553
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2554
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2555
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2556
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2557
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2558
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2559
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2560
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2561
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2562
Fuse: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2563
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2564
Fuse: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2565
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2566
Fuse: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2567
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2572
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2573
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2574
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2575
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2576
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2577
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2578
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2579
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2580
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2581
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2582
Fuse Block: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2583
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2584
Fuse Block: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2585
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2586
Fuse Block: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2587
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2590
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2591
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2592
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2593
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2594
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2595
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2596
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2597
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2598
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2599
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2600
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2601
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2602
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2603
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2604
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2605
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2606
Fuse Block: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2607
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2608
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2609
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2612
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2613
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2614
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2615
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2616
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2617
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2618
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2619
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2620
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2621
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2622
Fuse Block: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2623
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2624
Fuse Block: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2625
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2626
Fuse Block: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2627
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2632
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2633
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2634
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2635
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2636
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2637
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2638
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2639
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2640
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2641
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2642
Relay Box: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2643
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2644
Relay Box: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2645
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2646
Relay Box: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2647
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2650
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2651
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2652
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2653
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2654
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2655
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2656
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2657
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2658
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2659
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2660
Relay Box: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2661
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2662
Relay Box: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2663
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2664
Relay Box: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2665
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR LAMP (MIL)
Malfunction Indicator Lamp (MIL)
Check Engine, Service Engine Soon Or ISO Standard Engine Symbol
The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control
Module (PCM) has detected an OBD II emission-related component or system fault. When this
occurs, an OBD II Diagnostic Trouble Code (DTC) will be set.
^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or ISO standard engine symbol (Figure 16).
^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position.
^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster
proveout for approximately 4 seconds.
^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present.
- The instrument cluster will illuminate the MIL if the PCM does not send a control message to the
instrument cluster.
- The PCM is operating in the Hardware Limited Operation Strategy (HLOS).
- The MIL circuit is shorted to ground.
^ If the MIL remains off (during the bulb check): Bulb is damaged.
- MIL circuit is open.
^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three
consecutive drive cycles must be completed without a fault.
^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection.
^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist.
^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground
in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair > Resetting Oil Change Reminder Lamp
Oil Change Reminder Lamp: Service and Repair Resetting Oil Change Reminder Lamp
Oil Change Reset
Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized
oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of
12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL
CHANGE RESET control for five seconds. The message center will count down for five seconds.
After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have
established a personalized oil reset percentage, the display will show that percentage instead of
100%.) This reset procedure should be performed only after an oil change to ensure accurate oil
life indications.
Your personalized oil reset percentage allows you to establish a smaller oil change interval than
the manufacturer's recommended interval. To establish your personalized oil reset percentage:
1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display
is still counting gown the five seconds to
reset. The display will change to START OIL LIFE AT XXX%.
2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil
reset percentage you desire. Your choices are
100%, 90%, 80%, 70%, 60%, 50% 40% and 30%.
3. Press the RESET control to complete the procedure. Pressing any control other than RESET of
OIL CHANGE RESET will abort this
procedure and will not establish your new personalized oil reset percentage.
When your personalized oil reset percentage has been established, it will be used beginning with
the completion of your next OIL CHANGE RESET procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair > Resetting Oil Change Reminder Lamp > Page 2674
Oil Change Reminder Lamp: Service and Repair No Reset Oil Life Mode
The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: ^
DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE
GROUND COULD CAUSE THE VEHICLE TO MOVE.
^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT
THE VEHICLE FROM FALLING.
^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND
FALLING OFF THE JACK.
^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE
WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF
THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL
TRANSMISSION).
Jacking Points - Front
1. The front jacking point is a tab that extends from the lower control arm.
1. The rear jacking points are located on the rear axle tube.
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle
cover and adjoining differential housing surface may occur if a floor jack or any lifting device is
allowed to contact the cover at any point where the cover joins the housing.
LIFTING
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 2679
Lifting Points - 4x4
1. Locate front and rear hoist adapters on bottom lifting points as indicated.
CAUTION: ^
Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
^ Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2688
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2689
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2690
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2691
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2692
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2693
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2694
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2695
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2696
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2697
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance
Tires: Recalls Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2706
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2707
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2708
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2709
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2710
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2711
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2712
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment >
Page 2718
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2723
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2724
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2725
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2726
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2727
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2728
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2729
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2730
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2731
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2732
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement
Technical Service Bulletin # 00L12 Date: 010101
Information
00L12
SPECIAL FIELD ACTION
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Original - January 2001
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1, February 5, 2001 - Updated Information
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Supplement # 2, February 19, 2001 - Updated Information
All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2737
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2738
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2739
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2740
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2741
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2742
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2743
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2744
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2745
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2746
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2747
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2748
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2749
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2750
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2751
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2752
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2753
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2754
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2755
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2756
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2757
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2758
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2759
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2760
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label
Non-Compliance
Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2769
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2770
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2771
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2772
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2773
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2774
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2775
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page
2781
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement
Technical Service Bulletin # 00L12 Date: 010101
Information
00L12
SPECIAL FIELD ACTION
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Original - January 2001
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1, February 5, 2001 - Updated Information
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Supplement # 2, February 19, 2001 - Updated Information
All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2786
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2787
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2788
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2789
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2790
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2791
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2792
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2793
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2794
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2795
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2796
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2797
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2798
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2799
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2800
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2801
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2802
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2803
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2804
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2805
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2806
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2807
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2808
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2809
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Page 2810
Tires: Specifications
General Specifications
Wheel Rim Runout
Tire Runout Specifications
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Page 2811
Tires: Service and Repair
Removal
1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and
wheel bearings.
NOTE: To avoid damage or scratching to the center cap, place facing up when removed.
Loosen the wheel nuts.
1 Remove the center cap.
2 With the weight of the vehicle on the wheels, loosen the wheel nuts.
2. Raise and support the vehicle. 3. Remove the wheel and tire assembly.
1 Remove the wheel nuts.
2 Remove the wheel and tire assembly, using a side-to-side rocking motion.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel
nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are
loosened.
WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off
while the vehicle is in motion, possibly causing loss of vehicle control and collision.
Clean the wheel hub mounting surface and wheel pilot.
2. Install the tire and wheel assembly.
1 Position the tire and wheel assembly.
2 Install the wheel nuts hand-tight, then lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Page 2812
3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake
roughness, shudder and vibration.
Tighten the wheel nuts in a star pattern, using a torque wrench or torque sticks.
4. Install the center cap.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance
Wheels: Recalls Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 2826
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification
Label Non-Compliance
Wheels: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 2836
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 2837
Wheels: Specifications
General Specifications
Wheel Rim Runout
Tire Runout Specifications
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Wheel and Tire
Wheels: Service and Repair Wheel and Tire
Removal
1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and
wheel bearings.
NOTE: To avoid damage or scratching to the center cap, place facing up when removed.
Loosen the wheel nuts. 1
Remove the center cap.
2 With the weight of the vehicle on the wheels, loosen the wheel nuts.
2. Raise and support the vehicle.
3. Remove the wheel and tire assembly.
1 Remove the wheel nuts.
2 Remove the wheel and tire assembly, using a side-to-side rocking motion.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel
nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are
loosened.
WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off
while the vehicle is in motion, possibly causing loss of vehicle control and collision.
Clean the wheel hub mounting surface and wheel pilot.
2. Install the tire and wheel assembly.
1 Position the tire and wheel assembly.
2 Install the wheel nuts hand-tight, then lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Wheel and Tire > Page 2840
3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake
roughness, shudder and vibration.
Tighten the wheel nuts in a star pattern, using a torque wrench or torque sticks.
4. Install the center cap.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Wheel and Tire > Page 2841
Wheels: Service and Repair Wheel Leaks
1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
Wheel Bearing: Specifications
- Lubricate the new rear wheel bearing. ^
For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
- Lubricate the lip of the new wheel bearing oil seal. ^
Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications >
Page 2845
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of
the following actions.
^ On 4x2 vehicles, adjust the front wheel bearings.
^ On 4x4 vehicles, install a new wheel hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Ford
Wheel Bearing: Service and Repair Ford
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Special Tools
Special Tool(s)
Removal
1. Remove the axle shaft.
2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with
foreign material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.
Installation
1. Lubricate the new rear wheel bearing.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Ford > Page 2848
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Special Tool(s)
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Ford > Page 2849
NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
- Tighten the spindle nut while rotating the brake disc and hub.
- Loosen the spindle nut.
- Tighten the spindle nut while rotating the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
Wheel Nuts 135 Nm (100 lb/ft)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front
Wheel Fastener: Service and Repair Front
Removal
1. Remove the brake disc and hub.
2. CAUTION: Place shop towels between the pry bars and the brake disc to prevent damage to the
disc surface.
Using two pry bars, remove the ABS sensor ring. Discard the ABS sensor ring.
3. Using a suitable press, remove the wheel stud from the brake disc and hub.
Installation
1. Using a suitable press, install the wheel stud in the brake disc and hub.
2. CAUTION: When installing the ABS sensor ring, make sure the sensor ring is pressed on
straight.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 2859
Position a new ABS sensor ring on the hub. Using a cylinder with 79 mm (3.16 inch) inside
diameter and 96 mm (3.84 inch) outside diameter, press the ring onto the hub until the ring seats
against the shoulder in the hub.
3. Install the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 2860
Wheel Fastener: Service and Repair Rear
Special Tool(s)
Special Tool(s)
Removal
CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange,
wheel bearing or hub bearing can result.
1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove
the rear disc brake caliper, rear disc support bracket and brake disc, if so equipped. Support the
rear disc brake caliper with safety wire.
4. Using the C-Frame and Screw Assembly, press the wheel stud from its seat and discard.
Installation
CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud.
1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned
with those made by the original wheel stud.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 2861
2. Seat new wheel studs in the axle flange.
- Place four flatwashers over the outside end of the wheel stud.
- Thread a standard wheel nut with the flat side against the washers.
- Tighten the wheel nut until the wheel stud head seats against the back side of the flange.
3. Remove the wheel nut and flatwashers. 4. Install the brake disc, rear disc support bracket and
the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the
vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: ^
DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE
GROUND COULD CAUSE THE VEHICLE TO MOVE.
^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT
THE VEHICLE FROM FALLING.
^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND
FALLING OFF THE JACK.
^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE
WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF
THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL
TRANSMISSION).
Jacking Points - Front
1. The front jacking point is a tab that extends from the lower control arm.
1. The rear jacking points are located on the rear axle tube.
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle
cover and adjoining differential housing surface may occur if a floor jack or any lifting device is
allowed to contact the cover at any point where the cover joins the housing.
LIFTING
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
2865
Lifting Points - 4x4
1. Locate front and rear hoist adapters on bottom lifting points as indicated.
CAUTION: ^
Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
^ Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System
Variable Cam Timing System
Overview
The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine
speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the
exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the
combustion chamber. The residual gases cool the combustion chamber and are inert when mixed
with the incoming fresh charge of fuel and air. This results in better fuel economy and lower
Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas
Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature.
Variable Cam Timing
The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1)
on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT)
sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP)
sensor, Powertrain Control Module (PCM) (Figure 129).
1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature
(IAT) sensor, Engine Coolant
Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and
Crankshaft Position (CKP) sensor for determining the operating conditions of the engine.
2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are
met. The PCM disables the VCT system if
a fault is detected.
3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse
ring mounted on the exhaust camshaft.
Relative cam position is calculated by measuring the time between the rising edge of Profile
Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse.
4. The PCM continually calculates a cam position error value based on the difference between the
desired and actual position and a duty
cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit.
5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a
rotation motion from the helical mechanism in
the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve
to correct for cam position error.
Variable Cam Timing System
HARDWARE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2873
Variable Cam Timing (VCT) Solenoid Valve
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the
solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam
timing.
Variable Cam Timing Unit Assembly
Variable Cam Timing (VCT) Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2874
in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when
oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up
to 30 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2875
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit
Assembly
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum
overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The
camshaft is allowed to rotate up to 30 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Description and Operation
Variable Valve Timing Solenoid: Description and Operation
VARIABLE CAM TIMING (VCT) SOLENOID VALVE
Variable Cam Timing (VCT) Solenoid Valve
The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system.
The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the
PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or
retard the cam timing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 2882
Compression Check: Testing and Inspection
Compression Test General Remarks
NOTE: Removing fuses and disconnecting electrical components causes the powertrain control
module (PCM) to log an error message. After the measurements have been carried out this error
message should be cleared from memory by connecting to PDU.
NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this
can be adjusted).
The compression pressure should be checked with the engine at operating temperature.
Check The Compression Pressure
WARNING: On manual transmissions shift the transmission into neutral. On automatic
transmission vehicles, select "P". Failure to follow these instructions may result in personal injury.
1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds
then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter
switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank
the engine a
minimum of five compression strokes and record the highest reading. Note the approximate
number of compression strokes required to obtain the highest reading.
6. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes. 7. Install the components in reverse order, observing the specified tightening
torques. 8. Reset the PCM fault memory.
Interpretation of the Results
The indicated compression pressure are considered within specification if the lowest reading
cylinder is within 75% of the highest reading.
CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the
measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent
damage to the catalytic converter.
If the measurement on one or more cylinders is much lower than the specified value, spray some
engine oil into the combustion chamber and repeat the compression measurement. If the reading
greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either
damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other
are both too low then it is very likely that the cylinder head gasket between them is burnt through.
This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing
> Component Information > Specifications
Camshaft Bearing: Specifications
Camshaft Bearing Cap Bolts
................................................................................................................................... refer to
procedure in service and repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt Stage 1 50 Nm (37 lb-ft)
Stage 2 Additional 90 degrees
Camshaft Bolt 85 Nm (63 lb-ft)
The right-hand camshaft sprocket bolt is a left-handed
thread.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications
Camshaft: Specifications
Intake Lobe Lift 0.259 in
End Play 0.0003 - 0.007 in
Exhaust Lobe Lift 0.259 in
Maximum Allowable Lobe Lift Loss 0.005 in
Journal to Bearing Clearance 0.002 - 0.004 in
Journal Diameter 1.099 - 1.101 in
Bearing Inside Diameter 1.102 - 1.104 in
Maximum Camshaft Journal Runout 0.002 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > LH
Camshaft: Service and Repair LH
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Camshaft-LH
Removal 1. Remove the camshaft roller followers. 2. Remove the LH hydraulic camshaft tensioner.
3. Remove the bolt and the camshaft sprocket.
4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in the original
position.
Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply
tube.
5. Remove the camshaft.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > LH > Page 2895
1. NOTE: Lubricate the parts with clean engine oil before installing.
Install the camshaft.
2. NOTE: The camshaft bearing caps must be installed in the original position.
NOTE: After installing the bolts, check the camshaft for free rotation.
Position the oil supply tube, the camshaft bearing caps, and the bolts. ^
Tighten the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.).
3. The camshaft must be retimed. 4. Install the camshaft roller followers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > LH > Page 2896
Camshaft: Service and Repair RH
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Camshaft-RH
Special Tool(s)
Removal 1. Remove the camshaft roller followers. 2. Remove the RH hydraulic camshaft tensioner.
5. CAUTION: The right-hand camshaft sprocket bolt is a lefthand threaded bolt.
Using the special tool, remove the bolt and the camshaft sprocket.
4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in the original
position.
Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply
tube.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > LH > Page 2897
5. Remove the camshaft.
Installation
1. NOTE: Lubricate the parts with clean engine oil before installing.
Install the camshaft.
2. NOTE: The camshaft bearing caps must be installed in their original position.
NOTE: After installing the bolts, check the camshaft for free rotation.
Position the oil supply tube, the camshaft bearing caps, and the bolts. ^
Tighten the bolts in the sequence shown in two stages:
^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.).
3. The camshaft must be re-timed. 4. Install the camshaft roller followers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair
Lifter / Lash Adjuster: Service and Repair
Hydraulic Lash Adjusters
Removal and Installation
1. Remove the camshaft roller followers.
2. Remove the hydraulic lash adjusters.
3. NOTE: Lubricate the parts with clean engine oil prior to installing.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Roller Followers
Special Tools
Special Tool(s)
Removal
1. Remove the valve covers. 2. Remove the fuel supply manifold.
3. NOTE: Mark each camshaft roller follower to ensure its original position during reassembly.
Using the special tool, remove the camshaft roller followers.
4. NOTE: Lubricate the parts with clean engine oil prior to installing.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System
Variable Cam Timing System
Overview
The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine
speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the
exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the
combustion chamber. The residual gases cool the combustion chamber and are inert when mixed
with the incoming fresh charge of fuel and air. This results in better fuel economy and lower
Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas
Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature.
Variable Cam Timing
The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1)
on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT)
sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP)
sensor, Powertrain Control Module (PCM) (Figure 129).
1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature
(IAT) sensor, Engine Coolant
Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and
Crankshaft Position (CKP) sensor for determining the operating conditions of the engine.
2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are
met. The PCM disables the VCT system if
a fault is detected.
3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse
ring mounted on the exhaust camshaft.
Relative cam position is calculated by measuring the time between the rising edge of Profile
Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse.
4. The PCM continually calculates a cam position error value based on the difference between the
desired and actual position and a duty
cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit.
5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a
rotation motion from the helical mechanism in
the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve
to correct for cam position error.
Variable Cam Timing System
HARDWARE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2908
Variable Cam Timing (VCT) Solenoid Valve
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the
solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam
timing.
Variable Cam Timing Unit Assembly
Variable Cam Timing (VCT) Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2909
in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when
oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up
to 30 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2910
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit
Assembly
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum
overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The
camshaft is allowed to rotate up to 30 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications
Connecting Rod Bearing
Clearance to Crankshaft - Allowable
.....................................................................................................................................................
0.0005-0.002 inch Bearing Wall Thickness .........................................................................................
............................................................................. 0.0551-0.0554 inch
Connecting Rod
Rod Bearing Bore I.D. .........................................................................................................................
.............................................................. 2.237 inch Rod Bearing Bore Out-of-Round .........................
........................................................................................................................................... 0.0004
inch Rod Length Center to Center .......................................................................................................
......................................................... 5.746 - 5.749 inch Alignment (Bore-to-Bore Maximum
Difference) Twist .......................................................................................................... 0.0015 inch
per 1.000 inch Alignment (Bore-to-Bore Maximum Difference) Bend
......................................................................................................... 0.00049 inch per 1.000 inch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications > Page 2915
Connecting Rod Bearing: Service and Repair
Connecting Rod Bearings Clearance to Crankshaft Allowable
.........................................................................................................................................................
0.0005 - 0.002 inch Bearing Wall Thickness .......................................................................................
................................................................................. 0.0551 - 0.0554 inch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Connecting Rod Bolt
Connecting Rod: Specifications Connecting Rod Bolt
Install and tighten the connecting rod nuts finger tight.
Tighten the connecting rod nuts simultaneously in two stages:
^ Stage 1: Tighten 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten 90 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Connecting Rod Bolt > Page 2920
Connecting Rod: Specifications
Side Clearance (Assembled to Crankshaft) 0.092-0.268 mm
Piston Pin Bore or Bushing I.D. 23.958-23.976 mm
Rod Bearing Bore I.D. 56.82-56.84 mm
Rod Bearing Bore Out-of Round 0.01 mm
Rod Length Center to Center 145.965-146.035 mm
Alignment (Bore-to-Bore Max. Diff.) - Twist 0.038 mm per 25.4 mm
Alignment (Bore-to-Bore Max. Diff.) - Bend 0.0125 mm per 25.4 mm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications
Crankshaft Main Bearing: Specifications
Clearance to Crankshaft 0.0008 - 0.0015 in
Clearance to Crankshaft Allowable 0.0005 - 0.002 in
Bearing Wall Thickness 0.0709 - 0.0711 in
Main Bearing Cap Bolts 72 ft. lbs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Cylinder Bore Diameter 3.953 in
Maximum Cylinder Out-of-Round 0.001 in
Maximum Cylinder Taper 0.001 in
Main Bearing Bore Diameter 2.387 - 2.387 in
Crankshaft to Rear Face of Block Runout. TIR Maximum 0.005 in
Distributor Shaft Bearing Bore Diameter 2.852 - 2.853 in
Head Gasket Surface Flatness 0.004 inch Overall
Head Gasket Surface Finish RMS 60 - 150
Main Bearing Journal Diameter 2.243 - 2.244 in
Main Bearing Journal Runout Limit 0.002 in
Main Bearing Journal Taper Maximum Per Inch 0.003 in
Connecting Rod Journal Maximum Out-of-Round 0.003 in
Crankshaft Free End Play 0.002 - 0.0126 in
Main Bearing Journal Out-of-Round 0.003 in
Main Bearing Journal Runout TIR Maximum 0.002 in
Main Bearing Journal Runout Service Limit 0.005 in
Main Bearing Thrust Face Runout TIR Maximum 0.010 in
Thrust Bearing Journal Length 1.039 - 1.041 in
Main and Rod Bearing Journal Finish RMS Maximum 72 and 88
Main Bearing Thrust Face Finish RMS Maximum 20
Connecting Rod Journal Diameter 2.125 - 2.126 in
Connecting Rod Journal Taper Per Inch Maximum 0.0003 in
Clearance to Crankshaft Desired 0.0003 - 0.0024 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair
Engine Block Heater: Service and Repair
Block Heater
Removal and Installation
1. Drain the cooling system. 2. Raise the vehicle.
3. Disconnect the block heater power cable from the block heater.
4. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal.
Remove the block heater.
5. CAUTION: Make sure the power cable is routed and secured away from rotating or hot
components or damage to the cable may occur.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Pulley Bolt Stage 1 50 Nm (37 ft.lb)
Stage 2 Additional 90 degrees
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2933
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Pulley
Special Tools
Special Tool(s)
Removal
1. Remove the fan shroud. 2. Remove the accessory drive belt.
3. CAUTION: This bolt is torque to yield and cannot be reused.
Remove the damper bolt.
4. Using the special tool, remove the crankshaft pulley.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2934
1. Using the special tool, install the crankshaft pulley.
2. Install a new crankshaft pulley bolt.
^ Tighten the bolt in two stages:
^ Stage l: Tighten the bolt to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten the bolt an additional 90 degrees.
3. Install the accessory drive belt. 4. Install the fan shroud.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston Pin To Piston Pin Bore or Bushing I.D. 0.943 - 0.944 in
Bore Clearance Selective Fit 0.0012 - 0.002 in
Diameter-Coded STD 3.952 - 3.9528 in
Diameter-Coded 0.5 3.972 in
Diameter-Coded 1.0 3.990 - 3.991 in
Pin Bore Diameter (Red) 0.945 in
Pin Bore Diameter (Blue) 0.945 in
Top Ring Groove Width 0.0645 - 0.0654 in
Bottom Ring Groove Width 0.0705 - 0.0713 in
Oil Ring Groove Width 0.1378 - 0.1399 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Length 2.835 - 2.866 in
Diameter (Red) 0.9446 - 0.9447 in
Diameter (Blue) 0.9447 - 0.9449 in
To Piston Pin Bore Clearance 0.0004 - 0.0006 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Top Compression Ring Width 0.062 - 0.063 in
Bottom Compression Ring Width 0.068 - 0.069 in
Top Compression Side Clearance 0.002 - 0.0003 in
Bottom Compression Side Clearance 0.002 - 0.003 in
Top Compression Ring Gap 0.008 - 0.018 in
Bottom Compression Ring Gap 0.018 - 0.028 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does
not require adjustment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions > Page 2951
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Disconnect the battery ground cable.
2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure.
This may drain fuel from the system. Drain the fuel
into a suitable container.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions > Page 2952
Fuel Pressure Gauge
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Roller Followers
Special Tools
Special Tool(s)
Removal
1. Remove the valve covers. 2. Remove the fuel supply manifold.
3. NOTE: Mark each camshaft roller follower to ensure its original position during reassembly.
Using the special tool, remove the camshaft roller followers.
4. NOTE: Lubricate the parts with clean engine oil prior to installing.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH
Valve Cover: Service and Repair LH
Valve Cover - LH
Special Tool(s)
Removal and Installation
1. Disconnect the battery negative cable.
2. Detach the accelerator and speed control cables.
1 Detach the accelerator and speed control cables from the throttle body.
2 Detach the accelerator and speed control cables from the bracket, and position the cables aside.
3. Detach the spark plug wire retainer.
4. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2960
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Disconnect the spark plug wires.
5. Remove the bolts.
6. Remove the bolt.
7. Disconnect the coil electrical connector.
8. Disconnect the radio interference capacitor electrical connector and position the coil aside.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2961
9. Loosen the bolt and disconnect the electrical connector.
10. Disconnect the following:
1 Exhaust Gas Recirculation (EGR) valve vacuum hose.
2 EGR valve vacuum regulator solenoid vacuum hoses.
3 EGR valve vacuum regulator solenoid electrical connector.
4 Camshaft position sensor electrical connector.
5 Differential pressure feedback electrical connector.
11. Detach the spark plug wire retainer.
12. Disconnect the fuel vapor hose and the vacuum hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2962
13. Remove the bolt and position the electrical connector and bracket aside.
14. Remove the screws and the EGR valve vacuum regulator solenoid.
15. Remove the differential pressure feedback with the hoses from the exhaust manifold-to-EGR
valve tube.
16. Relieve the fuel system pressure.
17. Detach the clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2963
18. Using the special tool, disconnect the fuel supply line.
19. Remove the bolt and position the fuel supply line aside.
20. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube.
21. Disconnect the hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2964
22. Unscrew fitting.
23. Remove the bolts and the valve cover. 24. To install, reverse removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2965
Valve Cover: Service and Repair RH
Valve Cover - RH
Removal and Installation
1. Drain the cooling system.
2. Remove the air cleaner outlet pipe.
^ Disconnect the tube.
^ Detach the Mass Airflow (MAP) sensor wiring pushpin.
^ Loosen the clamps and remove the pipe.
3. Release hose clamps and remove hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2966
4. Remove hose.
5. Disconnect the vacuum hose.
6. Loosen hose clamps and disconnect hoses.
7. Release hose clamps and disconnect hoses.
8. Release hose clamp and disconnect hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2967
9. Release hose clamp and disconnect hose. Position hose aside.
10. Remove the bolts.
11. Detach the wiring harness retainer.
^ Remove the heater tube and bracket assembly.
12. Disconnect MAF sensor connector and wiring pushpin. Position wiring aside.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 2968
13. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Position the spark plug wires aside. 1
Disconnect the spark plug wires.
2 Disconnect the spark plug wire retainer and position the wires aside.
14. Disconnect fuel injector conductors. Position wiring aside.
15. Remove the bolts and the valve cover. 16. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications
Valve Guide: Specifications
Valve Guide Bore Diameter 0.276 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications
Valve Seat: Specifications
Width (Exhaust) 0.06 - 0.094 in
Width (Intake) 0.05 - 0.083 in
Angle Degrees 45 deg
Runout TIR Maximum 0.002 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL
ON, DTC P0300 or P0301 Set
Valve Spring: Customer Interest Engine Control - MIL ON, DTC P0300 or P0301 Set
Article No. 02-3-2
02/18/02
^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC
TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES
EQUIPPED WITH 4.0L SOHC ENGINE ONLY
^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES
EQUIPPED WITH 4.0L SOHC ENGINE ONLY
FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC,
RANGER
MERCURY: 1997-2002 MOUNTAINEER
ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT
"ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set
when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due
to system interaction of higher than expected transient exhaust system backpressure (under heavy
acceleration) coupled with valve spring resonance points experienced at these engine speeds. This
interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher.
ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust
valve springs and replace with new service intake and exhaust valve springs. Refer to the following
Service Procedure for details.
SERVICE PROCEDURE
NOTE
THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR
WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S.
NOTE
PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT
VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL
ON, DTC P0300 or P0301 Set > Page 2983
1. Gain access to the valve springs.
2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with
new service intake and exhaust valve springs 2L2Z-6513-AA.
NOTE
ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER
TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS.
3. Road test vehicle to verify repair.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6513 42
OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine
Control - MIL ON, DTC P0300 or P0301 Set
Valve Spring: All Technical Service Bulletins Engine Control - MIL ON, DTC P0300 or P0301 Set
Article No. 02-3-2
02/18/02
^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC
TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES
EQUIPPED WITH 4.0L SOHC ENGINE ONLY
^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES
EQUIPPED WITH 4.0L SOHC ENGINE ONLY
FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC,
RANGER
MERCURY: 1997-2002 MOUNTAINEER
ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT
"ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set
when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due
to system interaction of higher than expected transient exhaust system backpressure (under heavy
acceleration) coupled with valve spring resonance points experienced at these engine speeds. This
interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher.
ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust
valve springs and replace with new service intake and exhaust valve springs. Refer to the following
Service Procedure for details.
SERVICE PROCEDURE
NOTE
THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR
WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S.
NOTE
PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT
VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine
Control - MIL ON, DTC P0300 or P0301 Set > Page 2989
1. Gain access to the valve springs.
2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with
new service intake and exhaust valve springs 2L2Z-6513-AA.
NOTE
ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER
TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS.
3. Road test vehicle to verify repair.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6513 42
OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > Page 2990
Valve Spring: Specifications
Intake Valve Spring Compression Pressure at Specified Height 202.84 - 224.968 ft. lbs.
at 1.413 - 1.445 inch
Exhaust Valve Spring Compression Pressure at Specified Height 202.84 - 224.968 ft. lbs.
at 1.413 - 1.445 inch
Intake Valve Spring Free Length 1.7 in
Exhaust Valve Spring Free Length 1.7 in
Intake Valve Spring Assembled Height 1.569 - 1.601 in
Exhaust Valve Spring Assembled Height 1.569 - 1.601 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > Page 2991
Valve Spring: Service and Repair
Valve-Valve Spring
Special Tools
Special Tool(s)
Removal and Installation
1. Remove the camshaft roller followers. 2. Position the piston at top dead center. 3. Hold the valve
in the cylinder head.
^ Remove the spark plugs.
^ Use a suitable tool to apply air pressure to the cylinder.
4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the cylinder.
If air pressure must be removed, support the valve prior to removal.
Using the special tool, remove the valve spring retainer keys, the valve spring and the retainer.
5. Inspect the components.
6. NOTE: Lubricate the parts with clean engine oil prior to installing.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications
Valve: Specifications
Valve Stem Diameter Intake 0.274 - 0.275 in
Valve Stem Diameter Exhaust 0.274 in
Valve Stem to Guide Clearance Exhaust 0.001 - 0.003 in
Valve Stem to Guide Clearance Intake 0.001 - 0.002 in
Head Diameter Intake 1.807 - 1.815 in
Head Diameter Exhaust 1.531 - 1.539 in
Valve Face Angle Degrees 45 deg
Valve Face Runout Limit 0.001 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Specifications > Page 2999
Drive Belt: Service and Repair
Accessory Drive Belt
Removal and Installation
1. Remove the air cleaner outlet tube.
2. Remove the accessory drive belt.
1 Rotate the accessory drive belt tensioner counterclockwise.
2 Remove the belt.
3. NOTE: Refer to Component Locations for correct drive belt routing.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Service and Repair
Drive Belt Tensioner: Service and Repair
Accessory Drive Belt Tensioner
Removal and Installation
1. Remove the accessory drive belt.
2. Remove the accessory drive belt tensioner. 3. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair
Engine Mount: Service and Repair
Engine Support Insulators
Removal and Installation
1. Remove the fan shroud.
2. Remove the LH engine insulator nuts.
3. Remove the RH engine insulator nuts. 4. Raise and support the vehicle.
5. Remove the LH and RH engine support insulator nuts. 6. Raise and support the engine. 7.
Remove the engine support insulators. 8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Service and Repair
Idler Pulley: Service and Repair
Accessory Drive Belt Idler Pulley
Removal and Installation
1. Remove the accessory drive belt.
2. Remove the accessory drive belt idler pulley. 3. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure at 2000 rpm 40-60 psi
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications
Technical Service Bulletin # 02-1-9 Date: 020121
Engine Oil - Oil Recommendations/Applications
Article No. 02-1-9
01/21/02
ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30
MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY
FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002
ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002
FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER
1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002
LS 1998-2002 NAVIGATOR
MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999
TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001
MOUNTAINEER
This article is being republished in its entirety to update the vehicle models, engines and years
affected.
NOTE
PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A
COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB.
ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most
gasoline and flexible fueled vehicles.
ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the
recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to
improve fuel economy.
Testing has validated this viscosity grade can be used in many previous model year vehicles. It is
recommended ALL vehicles on the following Vehicle Application Listing be service with SAE
5W-20.
All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002
Vehicles" chart are being filled with SAE 5W-20
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3017
motor oil at the factory and should also be serviced with SAE 5W-20 oil.
Exception 2001 Vehicles
Exception 2002 Vehicles
NOTE
IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED.
REFER TO TSB 99-8-16.
Parts Block
OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000
Veh. App. Listing Approved For SAE 5W-20 Motor Oil
^ 1993-1996 1.9L Escort/Tracer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3018
^ 1995-2000 2.0L Zetec Contour/Mystique
^ 1999-2002 2.0L Cougar
^ 1997-2002 2.0L Escort/Tracer
^ 1998-2002 2.0L Escort ZX2
^ 2000-2002 2.0L Focus
^ 2001-2002 2.0L Escape
^ 1993-1997 2.3L Ranger
^ 1993-1994 2.3L Mustang
^ 1993-1994 2.3L Tempo/Topaz
^ 1998-2001 2.5L Ranger
^ 1995-2000 2.5L Contour/Mystique
^ 1999-2002 2.5L Cougar
^ 2001-2002 3.0L 4V Escape
^ 1996-2001 3.0L 4V Taurus/Sable
^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger,
^ Taurus/Sable (Flexible Fuel and Gas)
^ 1995-2000 3.0L (Vulcan) Windstar
^ 1993-1994 3.0L (Vulcan) Tempo/Topaz
^ 2000-2002 3.0L 4V Lincoln LS
^ 1995-2002 3.8L Windstar
^ 1993-1997 3.8L Taurus/Sable,
^ Thunderbird/Cougar, Continental
^ 1994-2002 3.8L Mustang
^ 2002-2002 3.9L 4V Lincoln LS
^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series
^ 1996-2002 4.6L 2V Mustang
^ 1992-2002 4.6L Crown Victoria/Grand Marquis
^ 1991-2002 4.6L Town Car
^ 1994-1997 4.6L 2V Thunderbird/Cougar
^ 1996-2002 4.6L 4V Mustang Cobra
^ 1995-2002 4.6L 4V Continental
^ 1993-1998 4.6L 4V Mark VIII
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3019
^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition
^ 1993-1999 4.9L E-Series, F-Series
^ 1993-1995 5.0L Mustang/Mustang Cobra
^ 1993-1993 5.0L Thunderbird/Cougar
^ 1997-2001 5.0L Explorer/Mountaineer
^ 1993-1996 5.0L E-Series, F-Series, Bronco
^ 2000-2002 5.4L Excursion
^ 1998-2002 5.4L 2V/4V Navigator
^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350
Chassis/RV/Cutaway
^ 1993-1997 5.8L F-Series, Bronco
^ 1993-1996 5.8L E-Series
^ 2000-2002 6.8L Excursion
^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway
^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome
^ 1993-1998 7.5L All Vehicles
NOTE
FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV.
NOTE
THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR
OIL
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Pressure, Vacuum and Temperature Specifications
Engine Oil: Pressure, Vacuum and Temperature Specifications
General Specifications
Oil Pressure At 2,000 Rpm ..................................................................................................................
................................................................. 40 - 60 psi
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3022
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................
............................................................. 4.7L (5.0 Qt)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3023
Engine Oil: Fluid Type Specifications
Engine Oil Type ...................................................................................................................................
............................................... SAE 5W-30 Motor Oil
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Lower Oil Pan
Oil Pan: Service and Repair Lower Oil Pan
Oil Pan
Removal and Installation
1. Raise and support the vehicle.
2. Drain the engine oil.
3. Remove the bolts and the oil pan.
4. NOTE: All sealing surfaces must be cleaned prior to assembly. Use metal surface cleaner to
clean the sealing surfaces.
NOTE: Inspect integral oil pan gasket for cuts or damage that may cause leaks. Install a new
gasket if necessary.
NOTE: Fill the engine with clean engine oil.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component
Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
With Instrument Gauge System Tester attached to the oil pressure switch connector and the
ignition switch lock cylinder in the RUN position (engine not running), set instrument Gauge System
Tester to infinite resistance. The center line of the pointer should fall on or below the L (low) mark.
Short the connector directly to engine ground. The centerline of the pointer should fall slightly
above mid-scale.
^ If the oil pressure gauge tests within calibration, install a new oil pressure switch.
^ If the oil pressure gauge still tests out of calibration, install a new gauge.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component
Information > Testing and Inspection > Page 3031
Oil Pressure Gauge: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair
Oil Pick Up/Strainer: Service and Repair
Oil Pump Screen and Pickup Tube
Removal and Installation
1. Remove the oil pan.
2. Remove the oil pump screen cover and tube. 3. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure at 2000 rpm 40-60 psi
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Intake Manifold Bolts 10 Nm (89 in.lb)
Throttle Body Bolts 9 Nm (80 in.lb)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 3045
Intake Manifold: Service and Repair
Intake Manifold
Removal and Installation
1. Disconnect the battery ground cable.
2. Remove the bolts and the shield.
3. Remove the air cleaner outlet pipe.
^ Disconnect the tube.
^ Detach the Mass Airflow (MAF) sensor wiring pushpin.
^ Loosen the clamps and remove the pipe.
4. Disconnect the Idle air control (IAC) valve and the Throttle Position Sensor (TPS) electrical
connectors. Disconnect the Exhaust Gas
Recirculation (EGR) valve vacuum hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 3046
5. Disconnect the accelerator and speed control cables.
1 Detach the accelerator and speed control cables from the throttle body.
2 Detach the accelerator and speed control cables from the bracket, and position the cables aside.
6. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube.
7. Disconnect the EGR valve vacuum regulator electrical connector and vacuum hoses.
8. Disconnect the hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 3047
9. Loosen the clamp and disconnect the brake booster vacuum hose.
10. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Disconnect the RH spark plug wires from coil. Remove spark plug wire routing clip pushpin and
position the wires aside.
11. Remove wiring harness bracket retainer, then position wiring harness aside.
12. Remove accelerator cable routing clip pushpin and wiring harness pushpin.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 3048
13. Remove the bolts.
14. Remove the bolt and position the coil and bracket aside.
15. Disconnect the vacuum hoses.
16. Remove the nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 3049
17. Disconnect the Powertrain Control Module (PCM) electrical connector.
18. Disconnect the ground wires and position the wiring harness aside.
19. Detach the electrical connector retainer.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 3050
20. Remove the intake manifold bolts and lift up the intake manifold.
21. Remove the heated PCV hose retainers and remove the heated PCV fitting. 22. Remove the
intake manifold. 23. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge >
Component Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
With Instrument Gauge System Tester attached to the oil pressure switch connector and the
ignition switch lock cylinder in the RUN position (engine not running), set instrument Gauge System
Tester to infinite resistance. The center line of the pointer should fall on or below the L (low) mark.
Short the connector directly to engine ground. The centerline of the pointer should fall slightly
above mid-scale.
^ If the oil pressure gauge tests within calibration, install a new oil pressure switch.
^ If the oil pressure gauge still tests out of calibration, install a new gauge.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge >
Component Information > Testing and Inspection > Page 3055
Oil Pressure Gauge: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Seal
Special Tool(s)
Material
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3060
Removal
1. Remove the flexplate or flywheel. 2. Remove the crankshaft spacer plate. 3. Remove the
crankshaft spacer.
4. CAUTION: Avoid scratching or damaging the crankshaft rear seal running surface during
removal of the crankshaft rear seal.
Using the special tool, remove the crankshaft rear seal.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3061
1. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To
clean the crankshaft rear seal surface area, use
extra-fine emery cloth or extra-fine 0000 steel wool with metal surface prep.
Lubricate the crankshaft rear seal with clean engine oil and install it on the special tool.
2. Install the special tools.
3. Position the crankshaft rear seal and the special tool.
4. Using the special tool, install the crankshaft rear seal. 5. Install the crankshaft spacer. 6. Install
the spacer plate. 7. Install the flexplate or flywheel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification
Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket
Identification
TSB 06-18-16
09/18/06
IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN
REMANUFACTURED ENGINES - SERVICE TIP
FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005
Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred,
Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003
Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport
2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53
Motorhome Chassis
LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004
Navigator, Navigator 2003-2004 Aviator 2006 Mark LT
MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005
Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner
ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured
engines, it is critical to determine the type of remanufactured engine that is being serviced, in order
to identify the correct replacement gasket.
ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for
originally equipment level thickness head gasket) or OVR (for oversized service level thicker head
gasket) remanufactured engine when replacing a head gasket.
SERVICE PROCEDURE
Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine
when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for
OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck,
milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed
when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this
additional information is available.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3066
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3067
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3068
For certain remanufactured engines, the long block assembly will be uniquely identified with a build
date, reman code, service part number, and serial number. This metal tag will be marked with STD,
or with OVR (Figures 1-6).
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3069
Technical Service Bulletin # 02-1-4 Date: 020121
Engine Head Gasket - Approved Replacement Procedures
Article No. 02-1-4
01/21/02
ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES
FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG,
TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E
SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002
BLACKWOOD
MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE
1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER
ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been
found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or
scratches and dents at the head to block mating surfaces.
ACTION Refer to the following Service Information for recommended gasket sealing surface
preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks
coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are
necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done
successfully utilizing leak detection methods such as a black light dye process.
SERVICE PROCEDURE
To sum up, a successful leak repair depends on:
^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures
^ Surface preparation and gasket installation using the approved tools, cleaners, and methods
^ Exercising CARE and CLEANLINESS during disassembly/assembly of components
^ Use of genuine Ford OEM replacement parts
^ Use of a Ford Remanufacturer
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 401000, 402000, 403000, 499000
Aluminum Cylinder Head - Removal From Engine
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3070
WARNING
ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH
EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE
ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF
THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT
AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A
BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH
SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE
BENCHTOP OR DAMAGE WILL OCCUR.
NOTE
SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD
BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS
THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL
ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN
HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE
HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN
PERIOD.
NOTE
IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF
THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR
HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR
THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE.
Place CLEAN shop towels over the cylinder block bores to prevent further contamination from
reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected
on the towel can fall on the engine if care is not exercised as it is removed.
Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other
impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or
the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively.
Contamination on these surfaces will cause leaks from "shimming" the head even under full head
bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak
path.
Inspection For Damage and Cleaning Procedure
The overall straightness of the cylinder head and block face is held within very tight specification.
Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary
equipment. Machining must meet manufacturer's specification on surface finish quality and be less
than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler
gauge. If the engine has been overheated the cylinder head may have been damaged or warped.
Re-surfacing will not correct this damage.
The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm).
There must not be any scratches or gouges present, especially those which track to another
sealing cavity or to the atmosphere.
Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion,
and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the
surface of any material, which could later interfere with the gasket's sealing ability.
WARNING
UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED
USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M
BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE
BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON
STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL
DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO
ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE
ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE
OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT
SOLVENT.
The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head
gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the
last torquing procedure either from the plant or a previous field repair. The new head bolt shanks
and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip
for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole.
The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt
particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and
cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out
the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces.
To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft
Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop
vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from
the block surface.
It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has
been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks.
The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid
contaminants. Any staining of the metal surface is considered normal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3071
Machining of aluminum heads and blocks is an unacceptable field practice for quality control
purposes of flatness and surface finish standards. Removing material will also raise the risk of
internal reciprocating components striking each other, as well as changing the emissions
calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable.
Ford Remanufacturers are authorized to perform this procedure and have the necessary
equipment to put the specified surface finish on the head within original factory limits.
Installation Onto the Cylinder Block Surface
WARNING
ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION
CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE
FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE
COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE
COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL
THEREBY TRIPPING FAULT CODES IN THE PCM.
Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or
liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner,
F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was
removed successfully from the surrounding areas of the block to head face of the head and the
block.
Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the
gasket surfaces to scrape or bang against other engine parts. The head may pick up material along
the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring
that the head is fully square, seated, and resting on the block deck in a level condition, install new
"torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year
Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the
intervals specified. Failure to follow these instructions may result in a warped head, and damaged
head bolt threads.
Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench.
Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt
the integrity of the bolt head and give a false reading on the final torque value of the fastener.
Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for
the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was)
primed properly and is in a "ready to start" condition with all engine oil galleys having been charged
with oil.
WARNING
DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL
PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW
HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN
THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE
INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND
STEADILY MAINTAINED.
Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks
around the gasket joints of the head, front cover, and associated component parts. The vehicle
should be road tested within normal guidelines to raise the engine to operating temperature and
verify the repair is sound.
Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to
levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
Crankshaft Front Oil Seal
Special Tool(s)
Removal
1. Remove the crankshaft pulley.
2. Using the special tool, remove the crankshaft front oil seal.
Installation
1. NOTE: Lubricate the seal lip with clean engine oil.
Using the special tools and install the crankshaft front oil seal.
2. Install the crankshaft pulley.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3083
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3084
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3085
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3086
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3087
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3088
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3089
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3090
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3091
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3092
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3093
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3094
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3100
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3101
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3102
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3103
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3104
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3105
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3106
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3107
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3108
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3109
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3110
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3111
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Valve-Valve Seals
Special Tools
Special Tool(s)
Removal
1. Remove the valve springs. 2. Remove the valve stem seals.
Installation
1. NOTE: Lubricate parts with clean engine oil prior to installing.
Using the special tool, install the valve stem seals.
2. Install the valve springs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt Stage 1 50 Nm (37 lb-ft)
Stage 2 Additional 90 degrees
Camshaft Bolt 85 Nm (63 lb-ft)
The right-hand camshaft sprocket bolt is a left-handed
thread.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3131
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3132
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3133
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3134
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3135
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3136
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3137
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3138
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3139
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3140
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3141
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3142
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3148
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3149
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3150
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3151
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3152
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3153
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3154
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3155
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3156
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3157
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3158
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3159
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3168
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3169
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3170
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3171
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3172
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3173
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3174
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3175
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3176
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3177
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3178
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3179
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3185
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3186
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3187
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3188
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3189
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3190
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3191
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3192
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3193
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3194
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3195
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3196
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair
Timing Cover: Service and Repair
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Engine Front Cover
Removal 1. Remove the radiator. 2. Remove the crankshaft pulley.
3. Remove the bolt and the wiring harness routing clip.
4. Remove the accessory bracket bolts and position the bracket aside. 5. Remove the drivebelt
tensioner.
6. Disconnect the generator wiring and position the wiring aside.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair > Page 3200
7. Remove the generator mounting bracket.
8. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
9. Remove the wiring anchors and position the wiring aside.
10. Remove the wiring harness retainer and position the wiring aside.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair > Page 3201
11. Remove the thermostat housing.
1 Remove the bolts.
2 Release the bypass hose clamp.
12. Release the hose clamp and remove the lower heater water hose.
13. Release the hose clamp and remove the lower radiator hose.
14. On A/C equipped vehicles, remove the A/C line bracket bolt and position the A/C line aside.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair > Page 3202
15. NOTE: The water pump is removed for clarity.
Remove the engine front cover.
Installation 1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces.
3. Apply silicone gasket and sealant to the front cover in two places.
4. Install the engine front cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair > Page 3203
5. On A/C equipped vehicles, install the A/C line bracket and bolt.
6. Install the lower radiator hose and clamp.
7. Install the lower heater water hose and clamp.
8. Install the thermostat housing.
1 Install the housing into the bypass hose.
2 Install the bolts.
3 Position the bypass hose clamp.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair > Page 3204
9. Position the wiring harness and install the bolt.
10. Secure the wiring anchors.
11. Connect the CKP sensor electrical connector.
12. Install the generator mounting bracket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair > Page 3205
13. Connect the generator wiring. 14. Install the drivebelt tensioner.
15. Install the accessory bracket bolts.
16. Install the routing clip and bolt. 17. Install crankshaft pulley. 18. Install the radiator. 19. Raise
and support the vehicle.
20. Drain the engine oil. 21. Lower the vehicle. 22. Fill the engine oil with clean engine oil. 23. Fill
the engine will coolant.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System
Variable Cam Timing System
Overview
The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine
speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the
exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the
combustion chamber. The residual gases cool the combustion chamber and are inert when mixed
with the incoming fresh charge of fuel and air. This results in better fuel economy and lower
Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas
Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature.
Variable Cam Timing
The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1)
on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT)
sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP)
sensor, Powertrain Control Module (PCM) (Figure 129).
1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature
(IAT) sensor, Engine Coolant
Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and
Crankshaft Position (CKP) sensor for determining the operating conditions of the engine.
2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are
met. The PCM disables the VCT system if
a fault is detected.
3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse
ring mounted on the exhaust camshaft.
Relative cam position is calculated by measuring the time between the rising edge of Profile
Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse.
4. The PCM continually calculates a cam position error value based on the difference between the
desired and actual position and a duty
cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit.
5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a
rotation motion from the helical mechanism in
the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve
to correct for cam position error.
Variable Cam Timing System
HARDWARE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System >
Page 3211
Variable Cam Timing (VCT) Solenoid Valve
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the
solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam
timing.
Variable Cam Timing Unit Assembly
Variable Cam Timing (VCT) Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System >
Page 3212
in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when
oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up
to 30 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System >
Page 3213
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit
Assembly
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum
overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The
camshaft is allowed to rotate up to 30 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Description and Operation
Variable Valve Timing Solenoid: Description and Operation
VARIABLE CAM TIMING (VCT) SOLENOID VALVE
Variable Cam Timing (VCT) Solenoid Valve
The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system.
The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the
PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or
retard the cam timing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information >
Page 3223
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3224
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3225
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the fuel injection supply manifold.
2. Remove the two bolts, the pressure relief valve and the O-ring seals.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > With Flexible Fuel
Idle Speed: Specifications With Flexible Fuel
With Automatic Transmission
Hot Idle ................................................................................................................................................
......................................................... 800 - 900 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
......................................................... 800 - 900 RPM
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > With Flexible Fuel > Page 3230
Idle Speed: Specifications Without Flexible Fuel
With Automatic Transmission
Hot Idle ................................................................................................................................................
......................................................... 760 - 880 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
......................................................... 760 - 880 RPM
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the lower air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service Precautions > Page 3238
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Disconnect the battery ground cable.
2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure.
This may drain fuel from the system. Drain the fuel
into a suitable container.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service Precautions > Page 3239
Fuel Pressure Gauge
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Coil Terminal-To-Cylinder Relationship
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications > Page 3243
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions
Ignition Cable: Service Precautions
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions > Page 3251
Ignition Cable: Service and Repair
Spark Plug Wire Remover
SPECIAL TOOL(S)
REMOVAL
1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug.
CAUTION: ^
Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the
ignition coil. 3. Disconnect the spark plug wires from the separators and remove the spark plug
wires.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the
exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of
the spark plug wire.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions > Page 3252
Spark Plug Wire Remover
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Spark Plug Gap
Spark Plug: Specifications Spark Plug Gap
Spark Plug Gap ...................................................................................................................................
.................................... 1.3-1.4 mm (0.052-0.056 in.)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Spark Plug Gap > Page 3257
Spark Plug: Specifications Spark Plug Torque
Spark Plug Torque ...............................................................................................................................
...................................................... 20 Nm (15 ft lbs)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3258
Spark Plug: Application and ID
RH Original Spark Plug .......................................................................................................................
.............................................................. AGRF22PG LH Original Spark Plug .....................................
...................................................................................................................................................
AGRF22P New Spark Plug (Either Side) ............................................................................................
................................................................................. AGSF22PP
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3259
Spark Plug: Service and Repair
REMOVAL
1. Remove the spark plug wires from the spark plugs.
2. Remove the spark plugs.
NOTE: ^
Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from.
New spark plugs can be used in any cylinder.
3. Inspect the spark plugs.
4. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3263
Compression Check: Testing and Inspection
Compression Test General Remarks
NOTE: Removing fuses and disconnecting electrical components causes the powertrain control
module (PCM) to log an error message. After the measurements have been carried out this error
message should be cleared from memory by connecting to PDU.
NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this
can be adjusted).
The compression pressure should be checked with the engine at operating temperature.
Check The Compression Pressure
WARNING: On manual transmissions shift the transmission into neutral. On automatic
transmission vehicles, select "P". Failure to follow these instructions may result in personal injury.
1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds
then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter
switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank
the engine a
minimum of five compression strokes and record the highest reading. Note the approximate
number of compression strokes required to obtain the highest reading.
6. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes. 7. Install the components in reverse order, observing the specified tightening
torques. 8. Reset the PCM fault memory.
Interpretation of the Results
The indicated compression pressure are considered within specification if the lowest reading
cylinder is within 75% of the highest reading.
CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the
measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent
damage to the catalytic converter.
If the measurement on one or more cylinders is much lower than the specified value, spray some
engine oil into the combustion chamber and repeat the compression measurement. If the reading
greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either
damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other
are both too low then it is very likely that the cylinder head gasket between them is burnt through.
This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does
not require adjustment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Water Pump
Water Pump: Specifications
Water Pump Bolts 89 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Water Pump > Page 3271
Water Pump: Specifications
Water Pump Pulley Bolts 18 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 3272
Water Pump: Service and Repair
Water Pump
Removal and Installation
1. Drain the engine cooling system. 2. Remove the accessory drive belt.
3. Remove the belt idler pulley.
4. Slide the water bypass hose clamp back.
5. Disconnect the heater hose at the water pump.
1 Release the clamp.
2 Remove the hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 3273
6. Disconnect the lower radiator hose at the water pump.
1 Release the clamp.
2 Remove the hose.
7. Remove the water pump pulley.
8. Remove the water pump.
9. NOTE: Use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing
surfaces.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System >
Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation
Hydraulic Cooling Fan Solenoid Valve: Description and Operation
HYDRAULIC COOLING FAN DRIVE
Hydraulic Cooling Fan Pump With Integral Solenoid
The system consists of an engine-driven pump with an integral solenoid (Figure 50) on the pump
that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting
current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current
means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always
turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump.
It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the
high pressure lines. The cooler is similar to the power steering cooler (same purpose and function,
to keep the fluid cool).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Engine Coolant - Propylene Glycol Recommendations
Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations
Article No. 01-23-6
11/26/01
^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON
ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL
^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION
ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS
FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002
CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR
2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO
1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002
EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F
SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER
SPORT 2000-2002 F-650, F-750
LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD
MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE
1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002
VILLAGER 1997-2002 MOUNTAINEER
MERKUR: 1989 SCORPIO, XR4TI
This article is being republished in its entirety to update the model year coverage.
ISSUE This TSB article describes Ford Motor Company's position on the use of propylene
glycol-based engine coolants.
ACTION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 3283
Ford Motor Company does not recommend nor endorse the use of engine coolants made with
propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene
glycol-based engine coolants.
Published information suggests that engine coolants made with propylene glycol may provide
engine cooling performance equivalent to engine coolants made with ethylene glycol. However,
different brands of engine coolant provide varying corrosion protection for the cooling system. Ford
does not have performance data for the multitude of engine coolants available in the aftermarket
and therefore cannot recommend the use of any coolant except those sold by Ford Customer
Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer
Service Division coolant for the vehicle.
Furthermore, claims of toxicological and environmental advantages of propylene glycol over
ethylene glycol may be misleading. When significant new information is developed, Ford will review
this policy.
Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene
glycol-based engine coolants. Those specifications do not refer to engine coolants made with
propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon
the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its
components, the cost of repairing the damage would not be covered by the Ford New Vehicle
Limited Warranty.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 402000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Pressure, Vacuum and Temperature Specifications
Coolant: Pressure, Vacuum and Temperature Specifications
Pressure Test
Cooling System ...................................................................................................................................
...................................................................... 20 psi
Thermostat Opening Temperature
Starts To Open ....................................................................................................................................
................................................ 183 - 190 degrees F Fully Open .........................................................
.......................................................................................................................................... 210
degrees F
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Pressure, Vacuum and Temperature Specifications > Page 3286
Coolant: Capacity Specifications
Cooling System Capacity 14.0 qt (US)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Pressure, Vacuum and Temperature Specifications > Page 3287
Coolant: Fluid Type Specifications
Antifreeze Type Ford Premium Engine Coolant (Green in color)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Service and Repair
Coolant Reservoir: Service and Repair
Coolant Expansion Tank
Removal and Installation
1. Remove the air cleaner outlet tube and the engine air cleaner.
2. Remove the bolt and position the speed control servo aside.
3. Disconnect the windshield washer hose from under the dash panel and plug the end of the hose.
4. Disconnect the windshield washer pump electrical connector from the windshield washer
reservoir.
5. Disconnect and plug the overflow hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Service and Repair > Page 3291
6. Remove the two nuts and bolts, and the coolant expansion tank. 7. To install, reverse the
removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Service and Repair
Fan Blade: Service and Repair
Cooling Fan
Removal and Installation
1. Remove cooling fan shroud.
2. Remove the bolts.
3. Separate the fan blade from the fan clutch. 4. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Tools and Equipment
Fan Clutch: Tools and Equipment
Fan Clutch Holding Tool AST tool# 8005
Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan.
2009 Suggested user price: $41.20
Assenmacher Specialty Tools 1 800 525 2943
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan
Solenoid Valve > Component Information > Description and Operation
Hydraulic Cooling Fan Solenoid Valve: Description and Operation
HYDRAULIC COOLING FAN DRIVE
Hydraulic Cooling Fan Pump With Integral Solenoid
The system consists of an engine-driven pump with an integral solenoid (Figure 50) on the pump
that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting
current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current
means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always
turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump.
It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the
high pressure lines. The cooler is similar to the power steering cooler (same purpose and function,
to keep the fluid cool).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3306
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3307
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
2. Remove the retaining clip and the ECT sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor
> Page 3312
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Temperature Sensor (Gauge) > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Temperature Sensor (Gauge) > Component Information > Diagrams > Page 3316
Temperature Sensor (Gauge): Service and Repair
Sender Unit-Water Temperature Indicator
Removal and Installation
1. Partially drain the cooling system. 2. Remove the thermostat.
3. Disconnect the electrical connector.
4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal
procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair
Fan Shroud: Service and Repair
Cooling Fan Shroud
Special Tool(s)
Removal and Installation
1. Remove the air cleaner outlet tube.
2. Using the special tools remove the fan blade and clutch assembly.
3. Remove the bolts, and the fan blade and shroud. 4. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component
Information > Service and Repair
Heater Control Valve: Service and Repair
REMOVAL
1. Prepare the vehicle for heater water control valve assembly removal.
1 Drain the engine coolant.
2 Remove the air cleaner assembly.
2. Disconnect the vacuum hose and heater hose.
3. Remove the retaining pins. Position the inner fender well access mat out of the way.
4. Disconnect the heater hose. Remove the bolt and the heater water control valve assembly.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the coolant hoses with MERPOL(R) meeting Ford specification ESE-M99B144-B or
plain water only, if needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3331
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3332
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3338
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3339
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3340
Heater Core: Service Precautions
WARNING:
- CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY
TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE,
ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE
CLOSED AREA.
THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS
WORKING CORRECTLY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3341
Heater Core: Description and Operation
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3342
Heater Core: Testing and Inspection
WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS
NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED ARE IN SUCH AS
A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES
OUTSIDE THE CLOSED AREA.
1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow
the heater core tube to the heater core and appear as a leak in the heater core.
NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good
and did not require installation of a new heater core. If a heater core leak is suspected, the heater
core must be tested by following the plugged heater core component test before the heater core
pressure test. Carry out a system inspection by checking the heater system thoroughly as follows:
2. Check the integrity of the heater water hose clamps.
NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at the heater water hose connection and damage the
heater core.
Heater Core-Plugged
WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE
SYSTEM IS WORKING CORRECTLY.
1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the
heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose
to see if it is hot.
If it is not hot: the heater control valve is not working correctly.
- the heater core may have an air pocket.
- the heater core may be plugged.
- the thermostat is not working correctly.
Heater Core-Pressure Test Use Pressure Tester to carry out the pressure test. 1. Drain the coolant
from the cooling system.
NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water
hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter
BT-7422-A from the radiator/heater core
pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter
with hose clamps.
5. Attach the pump and gauge assembly from the Pressure Tester to the adapter. 6. Close the
bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7.
Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the
heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak,
remove the
heater core from the vehicle and carry out the bench test.
Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant
from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and
adapter to the core tubes. Then connect the radiator/heater core pressure
tester to the adapter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3343
4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3344
Heater Core: Service and Repair
REMOVAL 1. Prepare the vehicle for heater core removal.
1 Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator
Case/Service and Repair/ See: Heating and Air Conditioning/Evaporator Case/Service and Repair
2 Remove the Dash Board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel,
Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair
3 Remove the Powertrain Control Module (PCM), please refer to Powertrain
Management/Computers and Controls/Engine Control Module/Service and Repair/ See: Powertrain
Management/Computers and Control Systems/Powertrain Control Module/Service and Repair
NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
2. Remove the PCM heat sink
1 Remove the ground strap screw.
2 Remove the heat sink.
3. Remove the four nuts from the engine side of the dash panel. Position the plenum chamber on
the vehicle floor.
4. Remove the heater core cover.
1 Remove the screws.
2 Remove the heater core cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3345
5. Remove the heater core.
- During installation, be sure to install a new oval foam seal around the heater core inlet and outlet
tubes.
INSTALLATION 1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3354
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3355
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3361
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3362
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection
Temperature Gauge: Testing and Inspection
1. Disconnect water temperature indicator sender unit C1061. Connect one lead of Instrument
Gauge System Tester to water temperature indicator
sender unit C1061, circuit 39 (RD/WH), harness side and the other lead to ground.
2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine
coolant temperature gauge should indicate C (cold).
Key OFF.
3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge pointer should be in the one
quarter range to mid-range. Key OFF.
4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge should indicate H (hot). Key
OFF. Return to the Pinpoint Test. See: Instrument Panel, Gauges and Warning Indicators/Testing
and Inspection/Instrument Cluster/Pinpoint Tests
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Page 3367
Temperature Gauge: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair
Radiator: Service and Repair
Radiator
Removal and Installation
1. Drain the cooling system. 2. Remove the air cleaner outlet tube.
3. Disconnect and remove the overflow hose. 4. Remove the cooling fan shroud.
5. Disconnect the upper radiator hose from the radiator.
6. Disconnect the lower radiator hose from the radiator.
7. Disconnect the two transmission cooling lines.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 3371
8. Remove the two bolts and the radiator.
9. Position aside EVAP test port.
10. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 3377
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 3378
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
2. Remove the retaining clip and the ECT sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature Sensor > Page 3383
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page
3387
Temperature Sensor (Gauge): Service and Repair
Sender Unit-Water Temperature Indicator
Removal and Installation
1. Partially drain the cooling system. 2. Remove the thermostat.
3. Disconnect the electrical connector.
4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal
procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Testing and Inspection
Temperature Gauge: Testing and Inspection
1. Disconnect water temperature indicator sender unit C1061. Connect one lead of Instrument
Gauge System Tester to water temperature indicator
sender unit C1061, circuit 39 (RD/WH), harness side and the other lead to ground.
2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine
coolant temperature gauge should indicate C (cold).
Key OFF.
3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge pointer should be in the one
quarter range to mid-range. Key OFF.
4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge should indicate H (hot). Key
OFF. Return to the Pinpoint Test. See: Instrument Panel, Gauges and Warning Indicators/Testing
and Inspection/Instrument Cluster/Pinpoint Tests
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Testing and Inspection > Page 3391
Temperature Gauge: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
Thermostat starts to open 90-94 C (183-190 F)
Thermostat fully open 105 C (210 F)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 3395
Thermostat: Description and Operation
THERMOSTAT HEATER CONTROL
Thermostat Assembly With Heater Control
The primary objective for the thermostat heater control is for improvement in fuel economy and
thermal efficiency. The system consists of a high temperature (98°C/208°F in lieu of a 90°C/194°F)
thermostat (Figure 51)that has a resistive heater within the wax element. The heater is controlled
by the PCM dependent on engine speed, throttle position, engine load, vehicle speed, air charge
temperature, transmission oil temperature and engine coolant temperature.
During low speed, low load and low air charge temperature conditions, the thermostat heater is
OFF and the engine is allowed to operate at an elevated coolant temperature. This should result in
lower internal friction and higher thermal efficiency, both leading to improved fuel economy.
During high speed, high load, high temperature conditions (air charge, transmission oil or engine
coolant), the PCM output is energized with a duty cycle to the thermostat heater. This heats the
wax and forces the thermostat to rapidly open wider allowing extra coolant to flow from the radiator.
This will reduce the coolant temperature and improve with performance demand.
It should be noted that the heater is only capable of supplying a SMALL amount of additional heat
to the wax element; it is NOT capable of opening the thermostat alone. The thermostat is 100%
duty cycle for short calibrated time and than the duty cycle is reduce to a maximum of 70% on and
30% off.
Approximately, unheated, the thermostat will begin to open at a coolant temperature of 98°C
(208°F) and will be fully open at 115°C (239°F). Energizing the heater will reduce the opening
temperature to about 80°C (176°F) and the fully open temperature to 110°C (230°F).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 3396
Thermostat: Service and Repair
Thermostat
Removal and Installation
1. Drain the engine cooling system. 2. Remove the air cleaner outlet tube.
3. Remove the upper radiator hose extension.
4. Remove the bolts water outlet adapter and thermostat.
^ Inspect the O-ring seal, install a new O-ring seal if necessary.
5. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Water Pump
Water Pump: Specifications
Water Pump Bolts 89 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Water Pump > Page 3401
Water Pump: Specifications
Water Pump Pulley Bolts 18 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3402
Water Pump: Service and Repair
Water Pump
Removal and Installation
1. Drain the engine cooling system. 2. Remove the accessory drive belt.
3. Remove the belt idler pulley.
4. Slide the water bypass hose clamp back.
5. Disconnect the heater hose at the water pump.
1 Release the clamp.
2 Remove the hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3403
6. Disconnect the lower radiator hose at the water pump.
1 Release the clamp.
2 Remove the hose.
7. Remove the water pump pulley.
8. Remove the water pump.
9. NOTE: Use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing
surfaces.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur
Smell
Technical Service Bulletin # 02-21-6 Date: 021028
Engine Controls/Emissions - Exhaust Sulfur Smell
Article No. 02-21-6
10/28/02
^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST
^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST
FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
Article 02-16-6 is being republished in its entirety to update the Service Procedure and model
years.
ISSUE
Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This
may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst
temperature, and amount of sulfur present in the fuel.
ACTION
Identify year, model, and build date to identify appropriate service procedure. For applications that
require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best
longevity, similar to what would commonly be used for exhaust heat shield rattle issues.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur
Smell > Page 3413
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Service Procedure
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.0L
Vehicles Built 1/14/02 Through 12/02/2002
At latest level for engine calibration.
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors heading for additional information.
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
Vehicles Built Before 1/14/02
1. Verify that WDS is at the latest level, B21.0 or higher.
2. Reprogram the PCM with the latest calibration.
3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
4. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
5. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE THE CONVERTER.
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.6L
Vehicles Built Prior To 12/02/2002
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur
Smell > Page 3414
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
2001-2002 2 DOOR EXPLORER SPORT 4.0L
7/24/00 Through 3/4/02 With 5R55E Transmission
1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the
old catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration only.
4. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L
Vehicles Built After 3/27/02
At latest level for engine calibration and converter, no service action will improve the situation.
1. See Contributing Factors Heading for additional information.
3/4/02 Through 3/27/02
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-AB only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L M5R4 MANUAL TRANSMISSION
11/2/01 Through 3/4/02 With Manual Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 SPORT TRAC 4.0L 5R55E TRANSMISSION
11/2/01 Through 3/4/02 With 5R55E Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration.
4. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur
Smell > Page 3415
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
DRIVE SEQUENCE AFTER REPAIRS COMPLETED
Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle.
Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for
this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the
transmission gear state. The goal of the drive procedure is to maintain a constant high temperature
level in the exhaust system through the use of increased engine speed. The combination of
increased temperature and driving will provide a sulfur cleaning environment for the catalyst
system.
CONTRIBUTING FACTORS TO SULFUR SMELL
Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the
amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the
sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer
sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get
hot enough to burn out stored sulfur residue and can produce a sulfur odor.
For example:
^ Extended Idle - Increase sulfur odor
^ Stop and go driving - Increase sulfur odor
^ Trailer Towing - Decrease sulfur odor
^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor
^ Abrupt accel/decel - Decrease sulfur odor
^ Hotter driving conditions - Decrease sulfur odor
^ Hilly terrain - Decrease sulfur odor
^ Canceling Overdrive - Decrease sulfur odor
Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to
the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate
year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different
fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries
supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor.
Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an
increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not
cause any durability or safety concerns with vehicle operation.
To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on
their vehicle as a result of the fuel and driving environment which creates a condition where sulfur
has been stored in their exhaust system. The service action performed allows the sulfur to pass
through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of
the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the
"rotten egg smell" to that of a "burning match". The odor will cease with time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur
Smell > Page 3416
PCM Calibration Information
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur
Smell > Page 3417
SUPERSEDES:02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine
Controls/Emissions - Exhaust Sulfur Smell
Technical Service Bulletin # 02-21-6 Date: 021028
Engine Controls/Emissions - Exhaust Sulfur Smell
Article No. 02-21-6
10/28/02
^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST
^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST
FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
Article 02-16-6 is being republished in its entirety to update the Service Procedure and model
years.
ISSUE
Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This
may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst
temperature, and amount of sulfur present in the fuel.
ACTION
Identify year, model, and build date to identify appropriate service procedure. For applications that
require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best
longevity, similar to what would commonly be used for exhaust heat shield rattle issues.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine
Controls/Emissions - Exhaust Sulfur Smell > Page 3423
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Service Procedure
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.0L
Vehicles Built 1/14/02 Through 12/02/2002
At latest level for engine calibration.
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors heading for additional information.
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
Vehicles Built Before 1/14/02
1. Verify that WDS is at the latest level, B21.0 or higher.
2. Reprogram the PCM with the latest calibration.
3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
4. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
5. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE THE CONVERTER.
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.6L
Vehicles Built Prior To 12/02/2002
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine
Controls/Emissions - Exhaust Sulfur Smell > Page 3424
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
2001-2002 2 DOOR EXPLORER SPORT 4.0L
7/24/00 Through 3/4/02 With 5R55E Transmission
1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the
old catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration only.
4. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L
Vehicles Built After 3/27/02
At latest level for engine calibration and converter, no service action will improve the situation.
1. See Contributing Factors Heading for additional information.
3/4/02 Through 3/27/02
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-AB only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L M5R4 MANUAL TRANSMISSION
11/2/01 Through 3/4/02 With Manual Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 SPORT TRAC 4.0L 5R55E TRANSMISSION
11/2/01 Through 3/4/02 With 5R55E Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration.
4. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine
Controls/Emissions - Exhaust Sulfur Smell > Page 3425
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
DRIVE SEQUENCE AFTER REPAIRS COMPLETED
Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle.
Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for
this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the
transmission gear state. The goal of the drive procedure is to maintain a constant high temperature
level in the exhaust system through the use of increased engine speed. The combination of
increased temperature and driving will provide a sulfur cleaning environment for the catalyst
system.
CONTRIBUTING FACTORS TO SULFUR SMELL
Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the
amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the
sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer
sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get
hot enough to burn out stored sulfur residue and can produce a sulfur odor.
For example:
^ Extended Idle - Increase sulfur odor
^ Stop and go driving - Increase sulfur odor
^ Trailer Towing - Decrease sulfur odor
^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor
^ Abrupt accel/decel - Decrease sulfur odor
^ Hotter driving conditions - Decrease sulfur odor
^ Hilly terrain - Decrease sulfur odor
^ Canceling Overdrive - Decrease sulfur odor
Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to
the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate
year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different
fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries
supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor.
Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an
increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not
cause any durability or safety concerns with vehicle operation.
To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on
their vehicle as a result of the fuel and driving environment which creates a condition where sulfur
has been stored in their exhaust system. The service action performed allows the sulfur to pass
through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of
the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the
"rotten egg smell" to that of a "burning match". The odor will cease with time.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine
Controls/Emissions - Exhaust Sulfur Smell > Page 3426
PCM Calibration Information
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine
Controls/Emissions - Exhaust Sulfur Smell > Page 3427
SUPERSEDES:02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3432
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3433
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3434
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3435
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3436
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3437
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3438
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3439
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3440
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3441
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3442
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3443
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3444
4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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Emissions/Engine Controls - Driveability Diagnosis > Page 3445
The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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Emissions/Engine Controls - Driveability Diagnosis > Page 3446
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine
Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine
Controls - Driveability Diagnosis > Page 3452
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Controls - Driveability Diagnosis > Page 3453
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions
Catalytic Converter: Description and Operation Acronyms and Definitions
2V - L
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
2V: Two Valve engine configuration.
4V: Four Valve engine configuration.
ABS: Anti-lock Brake System.
A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by
cooling and dehydrating the air.
ACC: Air Conditioning Clutch. Indicates status of the A/C clutch.
ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch.
ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel.
ACP: Air Conditioning Head Pressure or A/C cycling switch input state.
ACPSW: Air Conditioning Pressure Switch.
ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module
(PCM) from the ACP switch or sensor.
ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout
control during heavy acceleration.
A/D: Analog-to-Digital. Analog-to-Digital signal conversion.
ADC: See ATDC.
AFCM: Alternative Fuel Control Module.
AIR: Secondary Air Injection.
AIRB: Secondary Air Injection Bypass.
Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system
when the electric air pump is commanded on.
AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System
has been evaluated for OBD (On-Board Diagnostic) II purposes.
Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry.
AIRM: Secondary AIR pump monitor.
Ambient Air Temperature: Temperature of the air surrounding an object.
Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits
of the signal.
ARB: Air Resource Board.
ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by
Speed Control Command Switch (SCCS) inputs.
ASCII: American Standard Code for Information Interchange.
ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke.
Measured in degrees of crankshaft rotation.
AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale,
rather than a digital display.
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> Description and Operation > Acronyms and Definitions > Page 3469
AWD: All-Wheel Drive.
BARO: Barometric Pressure.
Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC
solenoid disconnected.
Base Timing: Spark advance in degrees before top dead center of the base engine without any
control from the PCM or ICM.
Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected
directly to the battery. Compare "Vehicle Power (VPWR)."
BAT TEMP: Battery Temperature.
BJB: Battery Junction Box.
BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness.
BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be
hydraulic or electric.
BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the
Brake Pedal Position (BPP) switch.
BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by
applying voltage to the control line.
BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its
stroke. Measured in degrees of crankshaft rotation.
Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to
module and to the DLC.
CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of
pressurized intake air.
CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which
govern fuel economy standards.
CANVNT: Canister Vent Solenoid.
Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine
exhaust emissions.
CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency
Monitor has successfully completed.
CCM: Comprehensive Component Monitor.
CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various
EEC components.
CD A through J: Coil Driver 1 through 10.
Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM)
and safety inspections.
CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case.
CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade.
CHTIL: Cylinder Head Temperature Indicator Lamp.
CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor
thermistor.
CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor.
CKP: Crankshaft Position. Senses the position of the crankshaft.
CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return.
CL: Closed Loop. An operating condition or mode which enables operation based on sensor
feedback.
CMP: Camshaft Position. Indicates camshaft position.
CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3470
CMS: Catalyst Monitor Sensor. Downstream H025.
CMVSS: Canadian Motor Vehicle Safety Standards.
CNG: Compressed Natural Gas.
CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust
emissions.
CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of
fuel.
Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to
increase voltage.
Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the
temperature of external and internal components stabilize.
CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs
generated during Continuous Memory Self-Test.
Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM
whenever the vehicle is operating.
CPP: Clutch Pedal Position. Indicates clutch pedal position.
CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the
clutch pedal is depressed.
CQIS: Common Quality Indicator System.
CSE GND: Case Ground.
CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to
obtain the air/fuel mixture appropriate for closed throttle operation.
CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer.
Data Communications Link: A communication path between various in-vehicle electronic modules.
Accessed by scan tools through the Data Link Connector (DLC).
DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage
measurement of ON time versus the full cycle period, expressed in percent.
DCL: Data Communication Link.
DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a
distributor.
Digital: Controls process information by switching the current or voltage ON and OFF.
DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information.
DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above
the valves.
DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument
cluster.
DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure
transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator
Valve.
DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other
unwanted deposits.
DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while
the vehicle is operating.
DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system.
DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the
On-Board Diagnostic System.
DVOM: Digital Volt-Ohm Meter.
E-85: Fuel containing 85% ethanol alcohol.
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> Description and Operation > Acronyms and Definitions > Page 3471
EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an
electric air pump.
EAIRM: Electric Secondary Air Pump circuit Monitor.
ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade.
ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor
thermistor.
ECU: Electronic Control Unit. A module that handles the control strategy and monitors system
inputs or outputs.
EEC: Electronic Engine Control system.
EEC-V: Fifth generation EEC system.
EFT: Engine Fuel Temperature.
EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade.
EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor.
EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade.
EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor.
EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into
the combustion chamber.
EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the
monitor is complete.
EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to
operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control.
EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when
energized by the PCM.
EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is
threaded into the bottom of the intake plenum.
EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM.
EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the
EGR valve by varying the duty cycle to the regulator.
EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the
commanded output.
EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists
in the EGRV circuit.
EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module
(ICM) integrated into the PCM.
EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition
System.
EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System.
EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay
operation or noisy generator contacts.
EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new
vehicles perform to design specifications.
EPA: Environmental Protection Agency (U.S. Government).
EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that
requires the electronic storage of information.
ESOF: Electronic Shift-on-the-Fly.
EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere.
EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the
evaporative purge canister.
EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists
for the current commanded state.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3472
EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system
canister from atmospheric pressure during the EVAP OBD II Monitor test.
Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal
which absorbs and holds fuel vapors.
EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap
Canister Purge Solenoid by the PCM.
EVO: Electronic Variable Orifice.
EWP: Electric Water Pump.
Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed
sensor.
FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays
OFF, LOW, or HIGH status.
FC: Fan Control.
FCS: Fuel Control Solenoid.
FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed.
FEAD: Front End Accessory Drive.
FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming
Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming.
FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that
displays the % alcohol content in fuel.
FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating
the inferred alcohol content of fuel.
FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is
reliable or not. Displays a YES or NO.
FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse
width.
FFV: Flexible Fuel Vehicle.
FIFO: First In First Out.
FILO: First In Last Out.
FIM: Fuel Indicator Module.
FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as
a percentage.
FLIV: Fuel Level Input Voltage.
FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle
function in the event of a PCM or EEC component failure.
FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2.
Fuel Pump (Modulated). Fuel pump duty cycle percentage.
FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump.
FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit.
FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults.
Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time.
FRP: Fuel Rail Pressure. Based on FRP V.
FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure
Sensor.
FSC: Fail-Safe Cooling.
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FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or
prevents Natural Gas flow to the fuel rail.
FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or
NO.
FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit.
FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts.
FTP V: Fuel Tank Pressure Voltage. From the FTP transducer.
FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump.
FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update.
FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1
(HEGO1).
FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2
(HEGO2).
FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP.
Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and
pressure from the fuel tank into the Evaporative Emission Control System.
FWD: Front Wheel Drive.
GEM: Generic Electronic Module.
GEN: Generator.
GENF: Generator Output Fault.
GENFDC: Generator Field Control Output.
GFS: Generator field signal monitor.
GND: Ground.
GPM: Grams Per Mile. Also known as Gallons Per Minute.
GPS: Global Positioning Satellite.
Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with
California on-board diagnostics.
GSS: Gear Select Solenoid.
GVW: Gross Vehicle Weight.
Hall Effect: A process where current is passed through a small slice of semi-conductor material and
a magnetic field to produce a small voltage in the semi-conductor.
Hard Fault: A fault currently present in the system.
HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2.
High Compression.
HCF: Hydraulic Cooling Fan.
HCFD: Hydraulic Cooling Fan Drive.
HFC: Hydraulic Cooling Fan.
HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit.
HFP: High Fuel Pump.
HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output
commands with fixed values in response to internal
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PCM malfunctions.
HO: High Output.
HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor.
Provides information on rich or lean exhaust conditions to the PCM.
Hot Soak: Period of time after an engine operates where localized combustion heat dissipates
throughout the engine.
HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the
HO2S sensor.
Hydrogen: Chemical symbol H. Highly flammable gas.
Hz: Hertz. Cycles per second.
IAC: Idle Air Control. Electrical control of throttle bypass air.
IAT: Intake Air Temperature.
IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor.
IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on
supercharged vehicles.
IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor.
IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit
functions.
ICM: Ignition Control Module. The module that controls the ignition system.
IFDM: Integrated Fuel Delivery Module.
IFS: Inertia Fuel Shutoff.
IGN GND: Ignition Ground.
Ignition: System used to provide high voltage spark for internal combustion engines.
IGNKEY(IGKY): Ignition Key status.
IGNSW (IGSW): Ignition Switch Position.
IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the
intake manifold.
IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults.
IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold.
INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output
from the PCM.
Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders.
Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion.
Intercooler: See CAC.
IPATS: Integrated Passive Anti-Theft System.
ISO: international Standards Organization.
KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even
when the vehicle is not operating.
KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM.
Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied
and the engine at rest.
Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the
engine running and the vehicle at rest.
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> Description and Operation > Acronyms and Definitions > Page 3475
KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position.
Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the
combustion chamber of an engine.
KOEC: Key On Engine Continuous.
KOEO: Key On Engine off.
KOER: Key On Engine Running.
KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.).
KPH: Kilometers Per Hour.
KS: Knock Sensor. Detects engine knock.
L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts.
LEV: Low Emissions Vehicle.
LFC: Low Fan Control.
LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps.
LIFO: Last In First Out.
LILO: Last In Last Out.
LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM.
LOOP: indicates OPEN or CLOSED loop status.
LPG: Liquefied Petroleum Gas.
LPLR: Low Pressure Low Resistance fuel injector.
M-V
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
M-85: Fuel containing 85% methanol alcohol.
MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine.
MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor.
MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold.
MFC: Medium Fan Control.
MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled.
MFP: Modulated Fuel Pump.
Microprocessor: A digital processor on a chip which perform arithmetic and control logic.
MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related
malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON."
MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the
crankshaft.
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> Description and Operation > Acronyms and Definitions > Page 3476
MON: Motor Octane Number.
Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter.
MSOF: Manual Shift-on-the-Fly.
MY: Model Year.
NA: Naturally Aspirated. Engine that is not supercharged or turbocharged.
NAAO: North American Automotive Operations.
NC: Normally Closed.
NG: Natural Gas. A system capable of using natural gas for vehicle operation.
NGS: New Generation STAR (Self-Test Automatic Readout) tester.
NGVM: Natural Gas Vehicle Module.
NO: Norm ally Open.
NO(x): Oxides of Nitrogen. Formed at high combustion temperatures.
NVH: Noise, Vibration, Harshness. A classification of vehicle concerns.
OASIS: On-Line Automotive Service Information System.
OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that
monitors PCM input and output control signals.
On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM.
OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO.
OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane.
OEM: Original Equipment Manufacturer.
OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the
valves.
OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp
ON when engine oil temperature exceeds safe limits.
Open Circuit: A circuit which does not provide a complete path for flow of current.
OL: Open Loop. An operating condition based on instructions not modified by PCM feedback.
O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen
content in exhaust gasses.
OSC: Output State Control.
OSS: Output Shaft Speed.
Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to
ultraviolet radiation.
Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines.
PATS: Passive Anti-Theft System.
PATSIL: Passive Anti-Theft System Indicator Light.
PATSIN: Passive Anti-Theft System Receive Signal.
PATSOUT: Passive Anti-Theft System Transmit Signal.
PATSTRT: Passive Anti-Theft System Starter Relay Control
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> Description and Operation > Acronyms and Definitions > Page 3477
PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control)
Processor.
PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase
vapors into the combustion chamber.
PF: Purge Flow. Amount of fuel vapor burned in the engine.
Photochemical: Term describing the action of light on air pollutants which results in creating smog.
PID: Parameter Identifier. Identifies an address in PCM memory which contains operating
information.
Powertrain: Engine and transmission/transaxle components.
Pressure - Absolute: A pressure referenced to a perfect vacuum.
Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude.
Sometimes called Barometric Pressure.
Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer.
Pressure - Differential: The pressure difference between two regions, such as between the intake
manifold and atmospheric pressure.
Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric
pressure.
PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization.
Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP
Sensor).
PPM: Parts Per Million. A measure used in emission analysis.
PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions.
Protocol: A set of rules for the exchange of information on a network.
PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed
information.
PSP: Power Steering Pressure. Indicates the pressure in the power steering system.
PSP V: Power Steering Pressure Input Voltage.
PTEC: Powertrain Electronic Controller.
PTO: Power Take-Off.
PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized.
PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle.
PWR GND: Power Ground. The main ground circuit in the EEC system.
Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and
Continuous Memory Self-Tests. Results are displayed as a series of DTCs.
RABS: Rear Antilock Brake System.
RAM: Random Access Memory. Memory into which information can be written as well as read.
REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate
at high temperatures.
Regulator: Controls the alternator/generator field current to maintain proper battery charge.
Contained within the PCM in smart charging applications.
Relay: An electromechanical device in which connections in one circuit are opened or closed by
changes in another circuit.
REM: Rear Electronic Module.
Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to
improve idle quality and improve emissions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3478
RF: Radio Frequency.
RFI: Radio Frequency Interference.
RFS: Returnless Fuel System.
RM: Relay Module. A module containing two or more relays.
ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered.
RON: Research Octane Number.
Routine: A group of related tasks, such as a series of diagnostic tests.
RPM: Revolutions Per Minute.
RS: Reverse Switch.
RTN: Return. A dedicated sensor ground circuit.
RWD: Rear Wheel Drive.
SAE: Society of Automotive Engineers.
SBS: Supercharger Bypass Solenoid or its signal output from the PCM.
SC: Supercharged or Supercharger.
SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from
the supercharger wastegate actuator to allow for maximum boost.
SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger
Bypass circuit.
SCICP: Supercharger Intercooler Pump Control.
SCICPF: Supercharger Intercooler Pump Control Fault.
SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump.
SCP: Standard Corporate Protocol.
Self- Test: See Quick Test.
Sensor: A device that detects the value or change in a physical quantity, such as temperature,
pressure or flow rate, and converts the data into an electrical signal.
SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is
individually energized and timed relative to its cylinder intake event.
Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic
Interference (EMI).
Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that
intended.
SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input
during closed-loop operation.
SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors.
SIL: Shift Indicator Lamp.
Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output
circuit.
SME: Society of Manufacturing Engineers.
SOF: Shift-On-the-Fly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3479
SOHC: Single Overhead Cam.
Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and
pulled to a central position.
ST: Scan Tool. A device that interfaces with and communicates information on a data link.
Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7
parts of air for every 1 part of fuel.
Switch: A device for making, breaking, or changing the connections in an electrical circuit.
TA: Traction Assist.
TACH: Tachometer.
TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has
an air bypass channel around the throttle plate.
TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel
slippage. 2. Turbocharger.
TDC: Top Dead Center.
Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration.
Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors.
Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees
before (BTDC) or after (ATDC) top dead center of the compression stroke.
TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to
measure intake air temperature.
TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate
information for the PCM.
TP V: Throttle Position Sensor Voltage.
Transducer: A device that receives energy from one medium and transfers it to another. For
example, thermal energy is converted to an electrical signal through a temperature probe.
Transmissions/Transaxles:
NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the
end.
TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns,
procedures, or general service information.
Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles
while running. Also used during engine crank.
Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure.
Variable Reluctance: A process of passing a varying magnetic field through wire windings and
inducing a voltage.
VCT: Variable Camshaft Timing.
VECI: Vehicle Emission Control Information label.
VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced.
Includes information about the year, model, engine, and plant origin of the vehicle.
VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister.
VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a
digital (DVOM) display.
VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare
"Battery Voltage
VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as
a reference by certain sensors.
WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain
other operating conditions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3480
Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger.
WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body.
Zip Tube: Another name for "fresh air duct" or "air inlet duct".
TRANSMISSIONS:
NOTE: The transmission naming convention is as follows:
^ The first character, a number, is the number of forward gears.
^ The second character, either the letter "F" or "R," represents front (transaxle) or rear
(transmission) wheel drive.
^ The next set of characters, a grouping of numbers, represents the design torque capacity of the
transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle).
^ The last character, if used, is one of the following:
^ "E" for electronic shift
^ "N" for non-synchronous shift
^
"S" for synchronous shift
^ "W" for wide ratio
^ 4F27E: Also known as the FN Focus automatic transmission.
^ 4F44E: Formerly known as the CD4E.
^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E.
^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E.
^ 4R44E: Formerly known as A4LD for 3.0L applications.
^ 4R55E: Formerly known as A4LD for 4.0L applications.
^ 4R70W: Formerly known as AOD-E.
^ 4R100: Formerly known as E4OD.
^ 5R44E: Formerly known as A5LD for 3.0L applications.
^ 5R55E: Formerly known as A5LD for 4.0L applications.
^ 5R55N: Lincoln LS automatic transmission.
^ 5R55W: Wide-ratio truck transmission.
^ 4x4L: 4x4 Low.
^ A/T: Automatic Transmission.
^ CCS: Coast Clutch Solenoid.
^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists.
^ EPC: Electronic Pressure Control.
^ EPCV: Electronic Pressure Control Volts.
^ ESS: Electronic Shift Scheduling.
^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E.
^ M5OD: Manual 5-Speed transmission with overdrive (RWD).
^ M/T: Manual Transmission/Transaxle.
^ NPS: Neutral Pressure Switch or its signal input to the PCM.
^ OCS: Overdrive Cancel Switch.
^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft.
^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear
Switch (NGS), and Transmission Switch Neutral (TSN).
^ REVERSE or REV: Transmission Reverse Switch Input.
^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual
transmission/transaxle vehicles.
^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission.
^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and
disengagement of the Torque Converter Clutch.
^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS)
has been activated.
^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled
transmissions.
^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between
an engine and transmission/transaxle.
^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid.
^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same
case. Front-wheel drive applications.
^ Transmission: A device which selectively increases or decreases the ratio of relative rotation
between its input and output shafts. Rear-wheel drive applications.
^ TR: Transmission Range. The range in which the transmission is operating.
^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to
the PCM on the transmission range selector position.
^ TR V: Transmission Range Voltage.
^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft.
^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is
proportional to vehicle speed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3481
Catalytic Converter: Description and Operation Catalyst Efficiency Monitor - Federal Test
Procedure
Catalyst Efficiency Monitor - Federal Test Procedure
The Catalyst Efficiency Monitor uses an oxygen sensor before and after the catalyst to infer the
hydrocarbon efficiency based on oxygen storage capacity of the catalyst. Under normal, close-loop
fuel conditions, high efficiency catalysts have significant oxygen storage. This makes the switching
frequency of the rear Heated Oxygen Sensor (HO2S) very slow and reduces the amplitude of those
switches as compared to the switching frequency and amplitude of the front HO2S. As the catalyst
efficiency deteriorates, its ability to store oxygen declines. The post-catalyst or downstream HO2S
signal begins to switch more rapidly with increasing amplitude, approaching the switching
frequency and amplitude of the pre-catalyst or upstream HO2S.
All applications utilize an FTP-based (Federal Test Procedure) catalyst monitor. This simply means
that the catalyst monitor must run during a standard FTP emission test as opposed to the
20-second steady state catalyst monitor used in 1994 through some 1996 vehicles. Two slightly
different versions of the catalyst monitor are used in the 2001 model year.
Switch Ratio Method (1996 - 2001)
1. In order to assess catalyst oxygen storage, the monitor counts front and rear HO2S switches
during part-throttle, close-loop fuel condition after
the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are
accumulated in up to nine different air mass regions or cells although three air mass regions is
typical. Rear switches are counted in a single cell for all air mass regions. When the required
number of front switches has accumulated in each cell, the total number of rear switches is divided
by the total number of front switches to compute a switch ratio. A switch ratio near 0.0 indicates
high oxygen storage capacity, hence high HC efficiency. A switch ratio near 1.0 indicates low
oxygen storage capacity, hence low HC efficiency. If the actual switch ratio exceeds a calibrated
threshold switch ratio, the catalyst is considered failed.
Inputs from Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) (warm
engine), IAT (not extreme ambient temperatures), Mass Air Flow (MAF) (greater than minimum
engine load), Vehicle Speed Sensor (VSS) (within vehicle speed widow) and Throttle Position (TP)
(at part-throttle) are required to enable the Catalyst Efficiency Monitor.
2. The DTCs associated with this test are Diagnostic Trouble Code (DTC) P0420 (Bank 1) and
P0430 (Bank 2). Because an Exponentially
Weight Moving Average algorithm is use for malfunction determination, up to six driving cycles may
be required to illuminate the Malfunction Indicator Lamp (MIL) during normal customer driving. If
Keep Alive Memory (KAM) is reset, a malfunction will illuminate the MIL in 2 drive cycles.
Index Ratio Method (some 2001 and beyond)
1. In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches
during part-throttle, closed-loop fuel conditions
after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are
accumulated in up to three different air mass regions or cells. While catalyst monitoring entry
conditions are being met, the front and rear HO2S signal lengths are continually being calculated.
When the required number of front switches has accumulated in each cell, the total signal length of
the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index
ratio. An index ratio near 0.0 indicates high oxygen storage capacity, hence high efficiency. A
switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual
index ratio exceeds the threshold index ratio, the catalyst is considered failed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3482
Inputs from ECT or CHT (warm engine), IAT (not extreme ambient temperatures), MAF (greater
than minimum engine load), VSS (within vehicle speed widow) and TP (at part-throttle) are required
to enable the Catalyst Efficiency Monitor.
2. The DTCs associated with this test are DTC P0420 (Bank 1) and P0430 (Bank 2). Because an
Exponentially Weighted Moving Average
algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate
the MIL during normal customer driving. If KAM is reset, a malfunction will illuminate the MIL in 2
drive cycles.
If the catalyst monitor does not complete during a particular driving cycle, the already accumulated
switch/signal data is retained in Keep Alive Memory and is used during the next driving cycle to
allow the catalyst monitor a better opportunity to complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3483
Catalytic Converter: Description and Operation Catalyst and Exhaust Systems
Catalyst and Exhaust System
Overview
The Catalytic Converter and Exhaust Systems (Figure 135) work together to control the release of
harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of
Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon
Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons
(HCs). CO, NO(x), and HCs are major air pollutants, and their emission into the atmosphere must
be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream
Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust
tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic
converter efficiency is monitored by the On Board Diagnostic (OBD II) system.
Generic Catalyst and Exhaust System
Catalytic Converter
A catalyst is a material that remains unchanged when it initiates and increases the speed of a
chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature.
The concentration of exhaust gas products released to the atmosphere must be controlled. The
catalytic converter assists in this task. It contains a catalyst in the form of a specially treated
honeycomb structure saturated with catalytically active precious metals. As the exhaust gases
come in contact with the catalyst, they are changed into mostly harmless products. The catalyst
initiates and speeds up heat producing chemical reactions of the exhaust gas components so they
are used up as much as possible.
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the
catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe
before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO),
unburned Hydrocarbons (HCs) and Oxides of Nitrogen (NO) in the exhaust emissions to an
acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a
muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly,
the exhaust emissions are directed to the atmosphere through an exhaust tailpipe.
HARDWARE
The downstream HO2S may be located after the light off catalyst or underbody catalyst. The
underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be
common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the
catalyst and exhaust system, refer to Exhaust System.
Three Way Catalytic Converter
The Three Way Catalytic (TWC) converter contains either platinum (Pt) and Rhodium (Rh) or
Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of
unburned HCs and CO and the reduction reaction of NO. The three-way conversion can be best
accomplished by always operating the engine air fuel/ratio at or close to stoichiometry.
Exhaust Manifold/Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of
cylinders.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3484
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
Upstream Heated and Downstream Heated Oxygen Sensors
The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas.
In addition to providing the PCM with indications of how rich/lean the engine is operating, the
upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is
an input to the Catalyst Efficiency monitor.
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine, and it also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3485
Catalytic Converter: Testing and Inspection
For information regarding diagnosis of this system refer to Computers and Control Systems
Diagnosis.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Service and Repair > Catalytic Converter-Dual Three-Way
Catalytic Converter: Service and Repair Catalytic Converter-Dual Three-Way
Catalytic Converter-Dual Three-Way
Removal and Installation
1. Raise and support the vehicle.
2. Disconnect the catalyst monitor sensor.
3. Remove the bolts and springs.
4. Loosen the LH nuts.
5. Loosen the RH nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Service and Repair > Catalytic Converter-Dual Three-Way > Page 3488
6. Remove the nuts.
7. Detach the dual three-way converter from the isolator and remove the converter.
8. Remove the gaskets and, if necessary, the catalyst monitor sensor.
^ Discard the gaskets.
9. CAUTION: Tighten the exhaust component fasteners starting from the rear of the vehicle.
NOTE: Make sure to apply anti-seize lubricant to the threads of the sensor prior to installation.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Service and Repair > Catalytic Converter-Dual Three-Way > Page 3489
Catalytic Converter: Service and Repair Dual Converter Y-Pipe
Dual Converter Y-Pipe
Removal and Installation
1. Remove the dual three-way catalytic converter.
2. Disconnect the heated oxygen sensors.
3. Remove the LH nuts.
4. Remove the RH nuts and remove the dual converter Y-pipe.
5. Remove the converter inlet gasket and, necessary, the heated oxygen sensors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Service and Repair > Catalytic Converter-Dual Three-Way > Page 3490
^ Discard the gasket.
6. CAUTION: Make sure that the dual converter Y-pipe to exhaust manifold nuts are tightened after
the three-way catalytic converter is installed.
NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Torque Specifications
Part 1 of 2
Part 2 of 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > LH
Exhaust Manifold: Service and Repair LH
Exhaust Manifold-LH
Removal and Installation
1. Raise and support the vehicle.
2. Remove the bolts. 3. Lower the vehicle.
4. Disconnect the hoses from the differential pressure feedback (EGR) transducer.
5. Disconnect the EGR valve to exhaust manifold tube from the exhaust manifold.
6. Disconnect the EGR valve to exhaust manifold tube from the EGR valve and remove the EGR
valve to exhaust manifold tube.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > LH > Page 3496
7. Remove the LH exhaust manifold.
8. NOTE: Use new exhaust manifold gaskets and nuts.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > LH > Page 3497
Exhaust Manifold: Service and Repair RH
Exhaust Manifold-RH
Removal
1. Raise and support the vehicle.
2. Remove the bolts. 3. Lower the vehicle.
4. Remove the RH exhaust manifold.
5. NOTE: Use new exhaust manifold gaskets and nuts.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair
Heat Shield: Service and Repair
Exhaust Heat Shield-Catalytic Converter and Muffler
1. Raise the vehicle.
2. Inspect the catalytic converter and muffler for loose or missing heat shields.
3. Install worm clamps for heat shields that are loose.
^ Use one of the following clamps: FOTZ-SA231-A or W705949-S300.
^ Trim off the excess ear of the worm clamp.
4. If the heat shields are missing, install new heat shields. If new heat shields are not available,
install a new catalytic converter. 5. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair
Muffler: Service and Repair
Muffler and Tailpipe
Removal and Installation
All vehicles 1. Raise and support the vehicle.
2. Remove the bolts and springs.
Sport Trac vehicles
3. Remove the bolt and position the shock absorber out of the way.
All vehicles
4. Remove the nut and position the right-hand stabilizer bar link out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 3504
5. Detach the tailpipe from the isolator.
6. Detach the muffler from the isolators and remove the muffler and tailpipe.
7. Remove the converter outlet pipe gasket.
^ Discard the gasket.
8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC
Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
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Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC
Replacement > Page 3516
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
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Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC
Replacement > Page 3517
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
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Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC
Replacement > Page 3518
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
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Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's
Powertrain Control Module: Customer Interest Instrument Panel - `Buzz' At Low Engine RPM's
Article No. 01-4-10
03/05/01
NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD
AT IDLE OR LOW SPEED DRIVING
FORD: 2001 EXPLORER
ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a
"buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving
with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control
Module (PCM) resonating against the heat shield that is located inside the PCM.
ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the
following Service Procedure for details.
SERVICE PROCEDURE
1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section
303-14 for removal procedure.
2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following
dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the
Rotunda Squeak and Rattle Kit, part number 164-R4900.
3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the
top surface of the module at the rear center of the module. This will dampen the buzz noise from
the PCM outer case. (Figure 1).
4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure.
5. Test drive vehicle to verify that the noise is corrected.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
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Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's >
Page 3523
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 702000, 702100, 702300
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Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine
Controls - General PCM Programming Procedures
Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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Controls - General PCM Programming Procedures > Page 3529
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
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Controls - General PCM Programming Procedures > Page 3530
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine
Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
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Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine
Controls - DTC P1635 Set After PCM/IC Replacement > Page 3535
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
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Controls - DTC P1635 Set After PCM/IC Replacement > Page 3536
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
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Controls - DTC P1635 Set After PCM/IC Replacement > Page 3537
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
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Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 >
Instrument Panel - `Buzz' At Low Engine RPM's
Powertrain Control Module: All Technical Service Bulletins Instrument Panel - `Buzz' At Low
Engine RPM's
Article No. 01-4-10
03/05/01
NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD
AT IDLE OR LOW SPEED DRIVING
FORD: 2001 EXPLORER
ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a
"buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving
with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control
Module (PCM) resonating against the heat shield that is located inside the PCM.
ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the
following Service Procedure for details.
SERVICE PROCEDURE
1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section
303-14 for removal procedure.
2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following
dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the
Rotunda Squeak and Rattle Kit, part number 164-R4900.
3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the
top surface of the module at the rear center of the module. This will dampen the buzz noise from
the PCM outer case. (Figure 1).
4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure.
5. Test drive vehicle to verify that the noise is corrected.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
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Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 >
Instrument Panel - `Buzz' At Low Engine RPM's > Page 3542
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 702000, 702100, 702300
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Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine
Controls - General PCM Programming Procedures
Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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Controls - General PCM Programming Procedures > Page 3548
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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Controls - General PCM Programming Procedures > Page 3549
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3550
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3551
Powertrain Control Module: Diagrams
Part 1
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3552
Part 2
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3553
Powertrain Control Module: Description and Operation
POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO)
The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem
generates vehicle speed information for distribution to the vehicle's electrical/electronic modules
and subsystems that require vehicle speed data. This subsystem senses the transmission output
shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired
signal or as a multiplexed data message.
The key features of the PCM-VSO system are to:
^ Infer vehicle movement from the output shaft sensor signal
^ Convert transmission output shaft rotational information to vehicle speed information
^ Compensate for tire size and axle ratio with a programmed calibration variable
^ Utilize a transfer case sensor for four wheel drive applications
^ Distribute vehicle speed information as a multiplexed message and/or an analog signal
The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft
Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is
sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per
mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into
the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing
changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information
can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM,
or by Speed and Odometer SCP multiplexed data messages.
The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT.
Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for
speed and distance data are transmitted as separate SCP messages over the SCP multiplex link.
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Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory
Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read
Only Memory
Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM
Description
Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an
Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the
vehicle strategy including calibration information specific to the vehicle and is capable of being
reprogrammed or reflashed repeatedly.
As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM as under Programming the VID Block for
a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block
not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can
also be tailored to accommodate various hardware changes made to the vehicle since production.
Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of
Acceptable Range. This is described under Making Changes to the VID Block and also under
Making Changes to the PCM Calibration. The VID block contains many items used by the strategy
for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane,
fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel
drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle
hardware and supported by the VID block will be displayed on the scan tool.
When changing items in the VID block, the strategy will place range limits on certain items such as
tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When
this limit is reached, the scan tool will display a message indicating the need to flash the PCM
again to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other
Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic
tool manufacturers users manual for details.
Programming the VID Block for a Replacement PCM
A new PCM will contain the latest strategy and calibration level for a particular vehicle. However,
the VID block will be blank and will need programming. There are two procedures available. The
first is an automatic data transfer from the old PCM to the new PCM and the second is manual data
entry into the new PCM.
Automatic data transfer will be performed if the old PCM is capable of communicating. This is done
by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The
stored data can now be downloaded to the new PCM after it has been replaced.
Manual data entry must be performed if the old module is damaged and is incapable of
communicating. Remove and replace the old PCM. You may be instructed to contact the "AS
BUILT" data center for the information needed to manually update the VID block with the scan tool.
Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M
technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed
World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or
"Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool.
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Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 3556
Powertrain Control Module: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the Powertrain Control Module (PCM) electrical connector.
3. Remove the nuts and the PCM cover.
4. Remove the PCM.
INSTALLATION
1. To install, reverse the removal procedure.
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- Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Diagram 700-01-00-1
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- Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3560
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- Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3561
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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- Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3562
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
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Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation
Air Injection Pump Relay: Description and Operation
SOLID STATE RELAY
Solid State Relay
The solid state relay (Figure 124) switches the high current required for operation of the electric
AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM).
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Diagram 700-01-00-1
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3571
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3572
Fuel Pump Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
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- Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Diagram 700-01-00-1
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Component Information > Locations > Page 3577
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Component Information > Locations > Page 3578
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Component Information > Locations > Page 3579
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and
Operation
Absolute Pressure Sensor: Description and Operation
THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR
Thermal Manifold Absolute Pressure (TMAP) Sensor
The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold
Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is
currently not being used. The MAP part of the sensor measures intake manifold air absolute
pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air
Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP)
sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced
into the intake manifold.
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> Locations
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Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Locations > Page 3588
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Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Locations > Page 3589
Mass Air Flow Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
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Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Locations > Page 3590
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
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> Locations > Page 3591
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Loosen the air cleaner outlet tube clamp and position the tube aside.
3. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
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Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
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3597
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3601
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION SWITCH
Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches
The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch
pedal position and, in some manual transmission applications, both the clutch pedal engagement
position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference
Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP
signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed,
indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output
voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1
volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or
PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the
clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP
switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the
5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load
information in mass air flow and fuel calculations.
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Information > Locations > Page 3606
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
2. Remove the retaining clip and the ECT sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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3610
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
3611
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Crankshaft Position (CKP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will
wear off after several engine revolutions.
^ Be sure the sensor wiring is routed away from the battery cable.
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Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
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Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
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Fuel Tank Pressure Sensor: Service Precautions
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
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Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure Sensor
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor
(Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles
equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank
pressure by forcing the system to purge.
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> Page 3622
Fuel Tank Pressure Sensor: Service and Repair
REMOVAL
1. Remove the fuel tank.
2. Remove the fuel tank pressure sensor.
1 Disconnect the electrical connector.
2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the
fuel tank.
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
System Leak Test
^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle
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3626
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3627
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE SENSOR
Intake Air Temperature (IAT)
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals
The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type
(Figure 37), are thermistor devices in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
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Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel spark and MAF.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above.
However, one is located before the supercharger at the air cleaner for standard OBD II/cold
weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control border-line spark and to help determine intercooler
efficiency.
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Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold.
3. Remove the KS.
1 Remove the bolt.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3638
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3639
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3645
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Technical Service Bulletins > Page 3653
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Diagrams > Diagram Information and Instructions
Heated Oxygen Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Circuit Identification Chart
System Codes Chart
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Sample Diagrams
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Sample Diagram
Sample Diagram
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Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Circuit Identification Chart
SYSTEM CODES CHART
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SAMPLE DIAGRAMS
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Diagrams > Diagram Information and Instructions > Page 3666
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3667
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3668
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3669
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3670
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3671
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3672
Heated Oxygen Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3673
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3674
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3675
Heated Oxygen Sensor: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3676
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Page 3677
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor Monitor
The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S
sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream
HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean
to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper
output voltage. The following illustration shows that input is required from the Engine Coolant
Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air
Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel
System Monitor and Misfire Detection Monitor must also have completed successfully before the
HO2S Monitor is enabled.
1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel
ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich
of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor
evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper
function.
2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response
frequency are checked. Excessive voltage is
determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A
fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S
heater circuit fault is determined by turning the heater on and off and looking for a corresponding
change in the Output State Monitor (OSM) and by measuring the current going through the heater
circuit. The HO2S Monitor DTCs can be categorized as follows:
The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130,
P1131, P1132, P1150, P1151 and P1152.
The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153.
The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151
and P0156.
The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and
P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in
on-demand is DTC P1127.
The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129.
3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive
drive cycles.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 3680
Heated Oxygen Sensor: Description and Operation PCM Inputs
HEATED OXYGEN SENSOR
Heated Oxygen Sensor (HO2S)
The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and
produces a variable voltage according to the amount of oxygen detected. A high concentration of
oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low
concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The
HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near
stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop
operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will
complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater
and heater control system are installed on some vehicles. The high power heater reaches closed
loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty
cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style
3.3 ohm heater.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Page 3681
Heated Oxygen Sensor: Service and Repair
Socket, Exhaust Gas Oxygen Sensor
SPECIAL TOOL(S)
REMOVAL
1. Raise and support the vehicle. 2. Remove the Three Way Catalytic Converter (TWC).
3. Using the special tool, remove the HO2S.
NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Page 3682
Socket, Exhaust Gas Oxygen Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3691
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3692
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3693
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3694
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3695
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3701
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3702
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3703
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3704
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3705
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3710
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3711
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3712
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3718
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3719
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3720
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3721
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3722
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3723
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3724
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3725
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR).
1 Disconnect the electrical connector.
2 Disconnect the hoses.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3729
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > PCM Inputs > Page 3732
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 3733
Throttle Position Sensor: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Remove the Throttle Position (TP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts and the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 3737
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 3738
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 3739
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 3740
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 3741
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor Bolt 98 - 115 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page
3745
Vehicle Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
Typical Vehicle Speed Sensor (VSS)
The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that
generates a waveform with a frequency that is proportional to the speed of the vehicle. If the
vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As
the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM
uses the frequency signal generated by the VSS (and other inputs) to control such parameters as
fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch
scheduling.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page
3746
Vehicle Speed Sensor: Service and Repair
Intermediate Shaft Speed (ISS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector.
3. Remove ISS sensor.
1. Remove the ISS sensor screw. 2. Remove the ISS sensor from the transmission.
^ Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the ISS sensor into the transmission. 2. Tighten ISS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page
3747
2. Connect ISS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3757
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3758
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3759
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3760
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3761
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 3767
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 3768
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 3769
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 3770
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 3771
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3776
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3777
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3778
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3784
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3785
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3786
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 3787
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 3788
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 3789
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 3790
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 3791
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR).
1 Disconnect the electrical connector.
2 Disconnect the hoses.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations > Page 3796
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations > Page 3797
Mass Air Flow Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations > Page 3798
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations > Page 3799
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Loosen the air cleaner outlet tube clamp and position the tube aside.
3. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation
Fuel Pressure Sensor/Switch: Description and Operation
FUEL RAIL PRESSURE SENSOR
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which
resistance changes with pressure. The electrical resistance of a strain gauge increases as
pressure increases, and decreases as pressure decreases. The varying resistance affects the
voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding
to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel
rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel
system. The differential fuel/intake manifold pressure together with measured fuel temperature
provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature
feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump
sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to
decrease.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
Inertia Fuel Shutoff Switch
The Inertia Fuel Shutoff (IFS) switch is on the RH A-pillar lower trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3806
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3807
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump.
The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel
ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the
magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the
switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset
before restarting the vehicle. Refer to the Owner Guide for the location of the IFS.
Inertia Fuel Shutoff (IFS) Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3808
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect
the electrical connector.
3. Remove the bolts and remove the IFS switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3812
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> PCM Inputs > Page 3815
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 3816
Throttle Position Sensor: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Remove the Throttle Position (TP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts and the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3821
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3822
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3823
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3827
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3828
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3829
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Crankshaft Position (CKP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will
wear off after several engine revolutions.
^ Be sure the sensor wiring is routed away from the battery cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder-Functional Lock Cylinder
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
3. To install, reverse the removal procedure.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 3835
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder
Removal and Installation
1. NOTE: Make sure the front wheels are in the straight-ahead position.
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and
instructions in the steering wheel
removal and installation procedure.
Remove the steering wheel assembly.
3. Twist off the cap from the ignition switch cylinder.
4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock
repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to
build the new lock cylinder to the current key code of the vehicle.
Remove the ignition switch lock cylinder. ^
Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch
lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the
steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 3836
5. Remove the bearing retainer.
6. Remove the bearing and gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
7. To install, reverse the removal procedure.
^ Install a new ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3840
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3841
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold.
3. Remove the KS.
1 Remove the bolt.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 3848
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 3849
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 3850
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the fuel injection supply manifold.
2. Remove the two bolts, the pressure relief valve and the O-ring seals.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > With Flexible Fuel
Idle Speed: Specifications With Flexible Fuel
With Automatic Transmission
Hot Idle ................................................................................................................................................
......................................................... 800 - 900 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
......................................................... 800 - 900 RPM
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > With Flexible Fuel > Page 3855
Idle Speed: Specifications Without Flexible Fuel
With Automatic Transmission
Hot Idle ................................................................................................................................................
......................................................... 760 - 880 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
......................................................... 760 - 880 RPM
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the lower air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions > Page 3863
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Disconnect the battery ground cable.
2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure.
This may drain fuel from the system. Drain the fuel
into a suitable container.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions > Page 3864
Fuel Pressure Gauge
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Coil Terminal-To-Cylinder Relationship
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications > Page 3868
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions
Ignition Cable: Service Precautions
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions > Page 3876
Ignition Cable: Service and Repair
Spark Plug Wire Remover
SPECIAL TOOL(S)
REMOVAL
1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug.
CAUTION: ^
Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the
ignition coil. 3. Disconnect the spark plug wires from the separators and remove the spark plug
wires.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the
exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of
the spark plug wire.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions > Page 3877
Spark Plug Wire Remover
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Spark Plug Gap
Spark Plug: Specifications Spark Plug Gap
Spark Plug Gap ...................................................................................................................................
.................................... 1.3-1.4 mm (0.052-0.056 in.)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Spark Plug Gap > Page 3882
Spark Plug: Specifications Spark Plug Torque
Spark Plug Torque ...............................................................................................................................
...................................................... 20 Nm (15 ft lbs)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3883
Spark Plug: Application and ID
RH Original Spark Plug .......................................................................................................................
.............................................................. AGRF22PG LH Original Spark Plug .....................................
...................................................................................................................................................
AGRF22P New Spark Plug (Either Side) ............................................................................................
................................................................................. AGSF22PP
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3884
Spark Plug: Service and Repair
REMOVAL
1. Remove the spark plug wires from the spark plugs.
2. Remove the spark plugs.
NOTE: ^
Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from.
New spark plugs can be used in any cylinder.
3. Inspect the spark plugs.
4. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 3888
Compression Check: Testing and Inspection
Compression Test General Remarks
NOTE: Removing fuses and disconnecting electrical components causes the powertrain control
module (PCM) to log an error message. After the measurements have been carried out this error
message should be cleared from memory by connecting to PDU.
NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this
can be adjusted).
The compression pressure should be checked with the engine at operating temperature.
Check The Compression Pressure
WARNING: On manual transmissions shift the transmission into neutral. On automatic
transmission vehicles, select "P". Failure to follow these instructions may result in personal injury.
1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds
then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter
switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank
the engine a
minimum of five compression strokes and record the highest reading. Note the approximate
number of compression strokes required to obtain the highest reading.
6. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes. 7. Install the components in reverse order, observing the specified tightening
torques. 8. Reset the PCM fault memory.
Interpretation of the Results
The indicated compression pressure are considered within specification if the lowest reading
cylinder is within 75% of the highest reading.
CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the
measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent
damage to the catalytic converter.
If the measurement on one or more cylinders is much lower than the specified value, spray some
engine oil into the combustion chamber and repeat the compression measurement. If the reading
greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either
damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other
are both too low then it is very likely that the cylinder head gasket between them is burnt through.
This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does
not require adjustment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Description and Operation
Absolute Pressure Sensor: Description and Operation
THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR
Thermal Manifold Absolute Pressure (TMAP) Sensor
The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold
Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is
currently not being used. The MAP part of the sensor measures intake manifold air absolute
pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air
Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP)
sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced
into the intake manifold.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Locations > Page 3899
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Locations > Page 3900
Mass Air Flow Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Locations > Page 3901
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Locations > Page 3902
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Loosen the air cleaner outlet tube clamp and position the tube aside.
3. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 3906
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 3907
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE SENSOR
Intake Air Temperature (IAT)
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals
The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type
(Figure 37), are thermistor devices in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 3908
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel spark and MAF.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above.
However, one is located before the supercharger at the air cleaner for standard OBD II/cold
weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control border-line spark and to help determine intercooler
efficiency.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle
Technical Service Bulletin # 03-3-5 Date: 030217
Engine Controls - No Start/Hard Start/Rough Idle
Article No. 03-3-5
02/17/03
DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS
FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 2000-2002 LS
MERCURY: 2000-2003 SABLE, MOUNTAINEER
ISSUE
Some vehicles, may exhibit drivability conditions.
These may include:
^ No start Difficult to start Stall
^ Low idle
^ Rough idle
^ High idle
^ Hesitation/surge while accelerating or at steady speed
These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction
Indicator Lamp (MIL). In some cases DTC and MIL may be evident.
ACTION
Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following
procedure is supplemental information to normal diagnostics to facilitate accurate identification of
malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling
problems, and Idle Speed Control System related DTC's.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3917
If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will
assist the technician making a correct repair the first time.
Perform normal diagnostics.
SERVICE INFORMATION
NOTE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3918
IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE
CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF
THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400,
698298
Disclaimer
IAC Diagnostic Service Tips - General
Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair
the drivability concern, but the long-term functionality of the valve is compromised.
For all drivability concerns, make certain the service writer obtains as much information as possible
from the customer as to the conditions causing drivability concern. Attached is a drivability concern
check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle.
NOTE
IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE
POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON
DECELERATION.
Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and
Lincoln LS.
1. Use the following conditions for the test described below:
^ Transmission in park
^ Engine temperature should be at least 190° F (88°C)
^ All accessories should be off steering wheel in the center position
^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system
^ Short and long term fuel trims less than 15%
^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission
Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the
chart in this TSB.
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure that there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird.
1. Use the following conditions for the test described below:
^ Transmission in park
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3919
^ Engine idle at approximately 650 RPM
^ Engine temperature should be at least 190° F (88° C)
^ All accessories and the engine cooling fan should be off
^ Steering wheel in the center position
^ EGRVR and EVAPDUTY CYCLE are zero
^ Short and long term fuel trims less than 15%
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
NOTE
IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650
RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER
THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND
CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM.
At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with
no purge flow (EVAPV duty cycle is 0%).
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
NOTE
IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY
CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER
DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN.
Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer,
Mountaineer, Explorer Sport and Explorer Sport Trac.
If no DTC's present check the following items in this order before examining the IAC valve:
^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB
^ Battery and fuse box power lead
^ Ground wire attachments
^ Wiring (wiggle test)
^ PCM voltage
^ Vacuum leaks
Examine AC valve under these conditions:
^ PCM updated to the latest available calibration
^ Transmission in park
^ Warm stabilized vehicle with engine temperature at least 190° F (88° C)
^ All accessories and cooling fan sh6uld be off
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3920
^ Steering wheel in the center position
^ EGVR and EVAPDC at zero, if the vehicle has an EGR system
^ Short and long term fuel trims (less than 15)
Perform the following steps in order:
1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3.
2. Allow vehicle to idle until the IACTRIM PID is 0.
NOTE
IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID
SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING
SHOULD BE TURNED OFF.
3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at
idle. The remainder of this TSB will help diagnose true root cause.
4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to
include the throttle body and air intake system) -is not operating properly.
NOTE
FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM
IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC.
IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns:
^ There are two primary causes of high idle:
1. Damaged IAC valves and
2. Vacuum leaks
^ AC valves can be damaged from engine induction backfires. Many times the customer may not
notice the induction backfire but will notice the high idle afterwards. Indications of valve damage
can be a shiny, almost polished appearance in the interior of the valve and a dislocated
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3921
pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1.
^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also
verify that the correct PCV valve is installed.
^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction
backfire can loosen or disconnect vacuum hoses.
^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear
normal in the service bay. If the duty cycle is below specification that is indicative that the engine is
receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to
restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS
(LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this
is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to
compensate.
IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle
Concerns:
^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on
the engine or obstruction in the air intake system could also reduce the engine RPMs.
^ There are four possible sources of friction load that can contribute to under speed error or low
idle concerns.
1. Power Steering Load
2. Air Conditioning Load
3. Electrical Load
4. Automatic Transmission Torque Converter Load
EAC Diagnostic Service Tips - Rough Idle
Concerns:
^ Rough idle concerns are often a result of a lean running condition
^ Another possible cause is contamination build up on the MAF sensor
EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start
^ While performing diagnostics, the technician should ensure that the fuel system is working
correctly for all engines with hard start/crank no-start complaints.
^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED
pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure
test:
^ Perform the KOEO fuel pressure test as specific in the PC/ED manual.
^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55
psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the
start of the test.
^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test.
^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible
after pump shut off, no more than 5 minutes after the start of the test.
NOTE
RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED
USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC.
IAC Diagnostic Service Tips - High Idle RPM at Start Up:
^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If
DTC 1506 is not present, this indicates that there is no fault present with the IAC.
^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast
idle (1600-2500 RPM that decreases slowly). No
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3922
repairs should be attempted because this is a normal temporary PCM calibration strategy to
prevent spark plug fouling during plant/transportation operation. The calibration will permanently
revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A
brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle
has been below 4 miles at a time.
IAC Diagnostic Service Tips - EAC Valve Noise Issues
For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire.
NOTE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3923
ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS
FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE
IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE
IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE,
COMPARE AGAINST A LIKE VEHICLE.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle
Technical Service Bulletin # 03-3-5 Date: 030217
Engine Controls - No Start/Hard Start/Rough Idle
Article No. 03-3-5
02/17/03
DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS
FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 2000-2002 LS
MERCURY: 2000-2003 SABLE, MOUNTAINEER
ISSUE
Some vehicles, may exhibit drivability conditions.
These may include:
^ No start Difficult to start Stall
^ Low idle
^ Rough idle
^ High idle
^ Hesitation/surge while accelerating or at steady speed
These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction
Indicator Lamp (MIL). In some cases DTC and MIL may be evident.
ACTION
Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following
procedure is supplemental information to normal diagnostics to facilitate accurate identification of
malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling
problems, and Idle Speed Control System related DTC's.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3929
If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will
assist the technician making a correct repair the first time.
Perform normal diagnostics.
SERVICE INFORMATION
NOTE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3930
IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE
CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF
THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400,
698298
Disclaimer
IAC Diagnostic Service Tips - General
Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair
the drivability concern, but the long-term functionality of the valve is compromised.
For all drivability concerns, make certain the service writer obtains as much information as possible
from the customer as to the conditions causing drivability concern. Attached is a drivability concern
check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle.
NOTE
IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE
POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON
DECELERATION.
Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and
Lincoln LS.
1. Use the following conditions for the test described below:
^ Transmission in park
^ Engine temperature should be at least 190° F (88°C)
^ All accessories should be off steering wheel in the center position
^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system
^ Short and long term fuel trims less than 15%
^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission
Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the
chart in this TSB.
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure that there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird.
1. Use the following conditions for the test described below:
^ Transmission in park
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3931
^ Engine idle at approximately 650 RPM
^ Engine temperature should be at least 190° F (88° C)
^ All accessories and the engine cooling fan should be off
^ Steering wheel in the center position
^ EGRVR and EVAPDUTY CYCLE are zero
^ Short and long term fuel trims less than 15%
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
NOTE
IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650
RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER
THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND
CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM.
At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with
no purge flow (EVAPV duty cycle is 0%).
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
NOTE
IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY
CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER
DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN.
Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer,
Mountaineer, Explorer Sport and Explorer Sport Trac.
If no DTC's present check the following items in this order before examining the IAC valve:
^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB
^ Battery and fuse box power lead
^ Ground wire attachments
^ Wiring (wiggle test)
^ PCM voltage
^ Vacuum leaks
Examine AC valve under these conditions:
^ PCM updated to the latest available calibration
^ Transmission in park
^ Warm stabilized vehicle with engine temperature at least 190° F (88° C)
^ All accessories and cooling fan sh6uld be off
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3932
^ Steering wheel in the center position
^ EGVR and EVAPDC at zero, if the vehicle has an EGR system
^ Short and long term fuel trims (less than 15)
Perform the following steps in order:
1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3.
2. Allow vehicle to idle until the IACTRIM PID is 0.
NOTE
IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID
SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING
SHOULD BE TURNED OFF.
3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at
idle. The remainder of this TSB will help diagnose true root cause.
4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to
include the throttle body and air intake system) -is not operating properly.
NOTE
FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM
IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC.
IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns:
^ There are two primary causes of high idle:
1. Damaged IAC valves and
2. Vacuum leaks
^ AC valves can be damaged from engine induction backfires. Many times the customer may not
notice the induction backfire but will notice the high idle afterwards. Indications of valve damage
can be a shiny, almost polished appearance in the interior of the valve and a dislocated
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3933
pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1.
^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also
verify that the correct PCV valve is installed.
^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction
backfire can loosen or disconnect vacuum hoses.
^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear
normal in the service bay. If the duty cycle is below specification that is indicative that the engine is
receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to
restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS
(LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this
is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to
compensate.
IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle
Concerns:
^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on
the engine or obstruction in the air intake system could also reduce the engine RPMs.
^ There are four possible sources of friction load that can contribute to under speed error or low
idle concerns.
1. Power Steering Load
2. Air Conditioning Load
3. Electrical Load
4. Automatic Transmission Torque Converter Load
EAC Diagnostic Service Tips - Rough Idle
Concerns:
^ Rough idle concerns are often a result of a lean running condition
^ Another possible cause is contamination build up on the MAF sensor
EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start
^ While performing diagnostics, the technician should ensure that the fuel system is working
correctly for all engines with hard start/crank no-start complaints.
^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED
pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure
test:
^ Perform the KOEO fuel pressure test as specific in the PC/ED manual.
^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55
psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the
start of the test.
^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test.
^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible
after pump shut off, no more than 5 minutes after the start of the test.
NOTE
RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED
USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC.
IAC Diagnostic Service Tips - High Idle RPM at Start Up:
^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If
DTC 1506 is not present, this indicates that there is no fault present with the IAC.
^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast
idle (1600-2500 RPM that decreases slowly). No
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3934
repairs should be attempted because this is a normal temporary PCM calibration strategy to
prevent spark plug fouling during plant/transportation operation. The calibration will permanently
revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A
brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle
has been below 4 miles at a time.
IAC Diagnostic Service Tips - EAC Valve Noise Issues
For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire.
NOTE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3935
ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS
FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE
IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE
IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE,
COMPARE AGAINST A LIKE VEHICLE.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 3939
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 3940
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 3941
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component
Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component
Information > Diagrams > Page 3945
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION SWITCH
Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches
The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch
pedal position and, in some manual transmission applications, both the clutch pedal engagement
position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference
Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP
signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed,
indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output
voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1
volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or
PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the
clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP
switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the
5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load
information in mass air flow and fuel calculations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Computers and Control Circuit
Diode > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 3952
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 3953
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
2. Remove the retaining clip and the ECT sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 3957
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 3958
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 3959
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Crankshaft Position (CKP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will
wear off after several engine revolutions.
^ Be sure the sensor wiring is routed away from the battery cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3965
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3966
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3967
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3968
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3969
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3970
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3971
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3972
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3973
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3974
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3975
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3976
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3977
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3978
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3979
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3980
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3981
Data Link Connector: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3982
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3983
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3984
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02
> Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02
> Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3993
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
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[Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02
> Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3994
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
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> Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3995
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01
> Instrument Panel - `Buzz' At Low Engine RPM's
Powertrain Control Module: Customer Interest Instrument Panel - `Buzz' At Low Engine RPM's
Article No. 01-4-10
03/05/01
NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD
AT IDLE OR LOW SPEED DRIVING
FORD: 2001 EXPLORER
ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a
"buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving
with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control
Module (PCM) resonating against the heat shield that is located inside the PCM.
ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the
following Service Procedure for details.
SERVICE PROCEDURE
1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section
303-14 for removal procedure.
2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following
dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the
Rotunda Squeak and Rattle Kit, part number 164-R4900.
3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the
top surface of the module at the rear center of the module. This will dampen the buzz noise from
the PCM outer case. (Figure 1).
4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure.
5. Test drive vehicle to verify that the noise is corrected.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01
> Instrument Panel - `Buzz' At Low Engine RPM's > Page 4000
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 702000, 702100, 702300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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4006
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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4007
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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[Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page
4012
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
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4013
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
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4014
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's
Powertrain Control Module: All Technical Service Bulletins Instrument Panel - `Buzz' At Low
Engine RPM's
Article No. 01-4-10
03/05/01
NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD
AT IDLE OR LOW SPEED DRIVING
FORD: 2001 EXPLORER
ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a
"buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving
with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control
Module (PCM) resonating against the heat shield that is located inside the PCM.
ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the
following Service Procedure for details.
SERVICE PROCEDURE
1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section
303-14 for removal procedure.
2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following
dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the
Rotunda Squeak and Rattle Kit, part number 164-R4900.
3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the
top surface of the module at the rear center of the module. This will dampen the buzz noise from
the PCM outer case. (Figure 1).
4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure.
5. Test drive vehicle to verify that the noise is corrected.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 4019
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 702000, 702100, 702300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain
Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain
Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4025
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain
Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4026
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Page 4027
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Page 4028
Powertrain Control Module: Diagrams
Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Page 4029
Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Page 4030
Powertrain Control Module: Description and Operation
POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO)
The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem
generates vehicle speed information for distribution to the vehicle's electrical/electronic modules
and subsystems that require vehicle speed data. This subsystem senses the transmission output
shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired
signal or as a multiplexed data message.
The key features of the PCM-VSO system are to:
^ Infer vehicle movement from the output shaft sensor signal
^ Convert transmission output shaft rotational information to vehicle speed information
^ Compensate for tire size and axle ratio with a programmed calibration variable
^ Utilize a transfer case sensor for four wheel drive applications
^ Distribute vehicle speed information as a multiplexed message and/or an analog signal
The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft
Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is
sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per
mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into
the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing
changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information
can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM,
or by Speed and Odometer SCP multiplexed data messages.
The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT.
Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for
speed and distance data are transmitted as separate SCP messages over the SCP multiplex link.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read
Only Memory
Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read
Only Memory
Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM
Description
Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an
Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the
vehicle strategy including calibration information specific to the vehicle and is capable of being
reprogrammed or reflashed repeatedly.
As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM as under Programming the VID Block for
a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block
not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can
also be tailored to accommodate various hardware changes made to the vehicle since production.
Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of
Acceptable Range. This is described under Making Changes to the VID Block and also under
Making Changes to the PCM Calibration. The VID block contains many items used by the strategy
for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane,
fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel
drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle
hardware and supported by the VID block will be displayed on the scan tool.
When changing items in the VID block, the strategy will place range limits on certain items such as
tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When
this limit is reached, the scan tool will display a message indicating the need to flash the PCM
again to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other
Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic
tool manufacturers users manual for details.
Programming the VID Block for a Replacement PCM
A new PCM will contain the latest strategy and calibration level for a particular vehicle. However,
the VID block will be blank and will need programming. There are two procedures available. The
first is an automatic data transfer from the old PCM to the new PCM and the second is manual data
entry into the new PCM.
Automatic data transfer will be performed if the old PCM is capable of communicating. This is done
by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The
stored data can now be downloaded to the new PCM after it has been replaced.
Manual data entry must be performed if the old module is damaged and is incapable of
communicating. Remove and replace the old PCM. You may be instructed to contact the "AS
BUILT" data center for the information needed to manually update the VID block with the scan tool.
Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M
technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed
World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or
"Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read
Only Memory > Page 4033
Powertrain Control Module: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the Powertrain Control Module (PCM) electrical connector.
3. Remove the nuts and the PCM cover.
4. Remove the PCM.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Description and Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 4038
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pump Signal > Component
Information > Description and Operation
Fuel Pump Signal: Description and Operation
FUEL PUMP MONITOR
Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control
The Fuel Pump Monitor (FPM) circuit is spliced into the Fuel Pump Power (FP PWR) circuit and is
used by the PCM for diagnostic purposes. The PCM sources a low current voltage down the FPM
circuit. With the fuel pump off, this voltage is pulled low by the path to ground through the fuel
pump. With the fuel pump off and the FPM circuit low, the PCM can verify that the FPM circuit and
the FP PWR circuit are complete from the FPM splice through the fuel pump to ground. This also
confirms that the FP PWR or FPM circuits are not shorted to power. With the fuel pump on, voltage
is now being supplied from the fuel pump relay to the FP PWR and FPM circuits. With the fuel
pump on and the FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel pump
relay to the FPM splice is complete. It can also verify that the fuel pump relay contacts are closed
and there is a B+ supply to the fuel pump relay.
Fuel Pump Driver Module Applications
Fuel Pump Driver Module Duty Cycle Signals, Part 1
Fuel Pump Driver Module Duty Cycle Signals, Part 2
The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the Powertrain
Control Module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the
FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Service Precautions
Fuel Tank Pressure Sensor: Service Precautions
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Service Precautions > Page 4045
Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure Sensor
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor
(Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles
equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank
pressure by forcing the system to purge.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Service Precautions > Page 4046
Fuel Tank Pressure Sensor: Service and Repair
REMOVAL
1. Remove the fuel tank.
2. Remove the fuel tank pressure sensor.
1 Disconnect the electrical connector.
2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the
fuel tank.
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
System Leak Test
^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4050
Idle Air Control Valve: Description and Operation
IDLE AIR CONTROL VALVE
Nippondenso Idle Air Control (IAC) Valve Assembly
Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter
The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed
and provides a dashpot function. The IAC valve assembly meters intake air around the throttle
plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the
desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle.
The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The
PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the
desired rpm.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4051
Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors
On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount
of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low
speed and light load conditions.
NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED.
The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the
internal diode is measured in crossed terminal position with a digital multimeter, there will be an
incorrect or negative reading. It is important that the mating component and harness connectors
correctly oriented. Diagnostic procedures emphasize this importance.
The PCM uses the IAC valve assembly to control:
^ No touch start
^ Cold engine fast idle for rapid warm-up
^ Idle (corrects for engine load)
^ Stumble or stalling on deceleration (provides a dashpot function)
^ Over-temperature idle boost.
^ Air Assist to Injectors.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4052
Idle Air Control Valve: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Disconnect the electrical connector, and remove the bolts and the Idle Air Control (IAC) valve.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network
<--> [Information Bus] > Component Information > Specifications
General Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network
<--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions
Module Communication Network: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network
<--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4058
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network
<--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4059
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Circuit Identification Chart
System Codes Chart
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Sample Diagrams
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Sample Diagram
Sample Diagram
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Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Circuit Identification Chart
SYSTEM CODES CHART
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SAMPLE DIAGRAMS
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Sample Diagram
Sample Diagram
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Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Symbols
Symbols
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Symbols
Symbols
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Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Module Communication Network: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Module Communication Network: Electrical Diagrams
DETAILED DIAGRAMS
Diagram 418-00-00-1
Diagram 418-00-00-2
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Diagram 418-00-00-3
Diagram 418-00-00-4
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Diagram 418-00-00-5
RELATED DIAGRAM
Diagram 501-12-00-1
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<--> [Information Bus] > Component Information > Description and Operation > Description and Operation
Module Communication Network: Description and Operation
The module communications network consists of the following items:
^ Generic Electronics Module (GEM)
^ Standard Corporate Protocol (SCP) communications network
^ International Standards Organization (ISO) communications network
^ Powertrain Control Module (PCM)
^ Anti-lock Brake Module (ABS)
^ Restraint Control Module (RCM)
^ Remote Anti-theft Personality (RAP)/central security module
^ Four-wheel Drive (4WD) control module (if equipped)
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Module Communication Network: Description and Operation Principles and Operation
The vehicle has two module communications networks. The Standard Corporate Protocol (SCP),
which is an unshielded twisted pair cable (data bus plus, circuit 914 [TN/OG] and data bus minus,
circuit 915 [PK/LB]); and the International Standards Organization (ISO) 9141 network which is a
single wire (circuit 70 [LB/WH]). The diagnostic tool can connect to both networks through the Data
Link Connector (DLC). This makes diagnosis and testing of these systems easier by allowing one
smart tester to be able to diagnose and control any module on the two networks from one
connector. The DLC can be found under the instrument panel between the steering column and the
radio.
The SCP communication network will remain operational even with the severing of one of the bus
wires. Communications will also continue if one of the bus wires is shorted to ground or voltage, or
if some, but not all, termination resistors are lost.
The ISO 9141 communication network does not permit inter-module communication. When the
diagnostic tool communicates to modules on the ISO 9141 communication network, the diagnostic
tool must ask for all information; the modules cannot initiate communications.
Unlike the SCP, the ISO 9141 communication network will not function if the wire is shorted to
ground or battery voltage. Also, if one of the modules on the ISO 9141 communication network
loses power or shorts internally, communications to that module will fail.
There is one module linked to the SCP communication network and five modules linked to the ISO
9141 communication network.
The Powertrain Control Module (PCM) is on the SCP communication network. The PCM controls
the engine for better fuel economy, emissions control and failure mode detection and storage.
The Restraint Control Module (RCM) is on the ISO 9141 communication network. The RCM
controls the deployment of the air bags based on sensor input.
The Generic Electronic Module (GEM) is on the ISO 9141 communication network. The GEM
controls a variety of systems:
^ windshield wipers
^ courtesy lamps
^ warning chimes
^ interior lamps
^ exterior lamps
^ power windows
For additional GEM information, refer to Multifunction Electronic Control Module (General Module).
The central security module (vehicles built after 7/24/2000) is on the ISO 9141 communication
network. The remote anti-theft personality (RAP) module (vehicles built before 7/24/2000) is on the
ISO 9141 communication network. The RAP/central security module controls the keyless remote
entry of the vehicle.
The Anti-lock Brake Control (ABS) module is on the ISO 9141 communication network. The ABS
module controls the brake pressure to the four wheels to keep the vehicle under control while
braking.
The Four-wheel Drive (4WD) control module is on the ISO 9141 communications network. The
4WD module controls all four-wheel drive functions including the 4WDLOW and 4WDHIGH
indicator lamps.
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Module Communication Network: Description and Operation Principles of Operation
Some modules must be programmed as part of the repair procedure. If this procedure is not
followed the module will not function correctly and may set a number of Diagnostic Trouble Codes
(DTCs), including B2477 or P1639, which indicate that some necessary data has not been
programmed into the module.
Modules that need programming should not be transferred between vehicles. In most cases the
parameter values or settings are unique to that vehicle, and if not set correctly will cause
malfunctions or faults.
Some programmable parameters, such as belt minder on/off, can be changed from the factory
setting at the customer's request.
WDS will automatically attempt to retrieve the module configuration information from all modules,
and from a backup location in the Powertrain Control Module (PCM) when Vehicle ID is carried out.
If the module and the PCM do not contain correct information the diagnostic tool will either request
"As Built" data or display a list of items that you will need to manually configure. The diagnostic tool
will program the module based on the data you enter.
There are three different methods that are used for module programming:
^ Programmable Module Installation (PMI)
^ calibration update
^ programmable parameters
Some modules do not support all three methods.
Programmable Module Installation (PMI) The programmable module installation (PMI) method is
used when a new programmable module is installed on the vehicle. It is no longer necessary to
command the diagnostic tool to gather module option content from the old module. The diagnostic
tool automatically obtains any available module option content information from the old module
during the Vehicle ID routine that runs when the diagnostic tool is initially connected to the vehicle.
It is important that you connect WDS to the vehicle and allow it to identify the vehicle and obtain
configuration data prior to removing any modules.
Calibration Update Calibration update is used to install a new calibration and strategy into a
module. The updates are usually issued to fix a concern in the module software and would
normally be addressed by a Technical Service Bulletin (TSB). This method has been used by the
PCM for several years. Other modules will be adopting this strategy as well.
Programmable Parameters This method is used to configure parameters that can be modified in
repair. These are typically at the preference of the customer. Not all features controlled by the
module are listed in this configuration method. Refer to the Module Configuration Index for a list of
features by system.
If a module that has been modified using programmable parameters needs to be installed, the PMI
procedure will maintain the parameters in their altered state if WDS is able to communicate with the
old module during Vehicle ID. Otherwise you may need to use programmable parameters to return
them to the altered state.
Vehicle Identification (VID) Block Some PCMs contain a memory area called a vehicle identification
(VID) block. The VID block is used to store backup data for each programmable module, as well as
powertrain configuration information.
If the diagnostic tool cannot retrieve module option content information from the suspect module,
the diagnostic tool will attempt to extract backup information from the PCM's VID block.
The PCM VID block contains the factory settings for the configurable modules unless the PCM is
flashed with a new calibration, in which case some PCM parameters may be modified.
As-Built Data Center The As-Built Data Center maintains a record of the vehicle configuration in a
database. The vehicles VIN is necessary to obtain this information. The As-Built Data Center
records the applicable module configurations stored in each module before the vehicle leaves the
factory. The As-Built Data Center will always reflect the original build of the vehicle as it left the
factory. Only contact the As-Built Data Center when directed to do so by the diagnostic tool.
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Module Communication Network: Testing and Inspection Module Communications Network
Initial Inspection
1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical
damage:
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse 17 (20A)
^ Damaged wiring harness
^ Loose or corroded connectors
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
If the diagnostic tool still does not communicate with the vehicle, go to Pinpoint Test I. See:
Pinpoint Tests/Pinpoint Tests/Test I: No Module/Network Communication
4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck)
PC1
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A1
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A2 - A3
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B1 - B3
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B3
C1
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C2 - C3
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D1 - D3
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D3
E1
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E2 - E3
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F1 - F2
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F2 - F3
Test G: No Module/Network Communication - ISO 9141 Network
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G1 - G3
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G3 - G4
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G5 - G6
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G7 - G8
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G9 - G11
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G11 - G12
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G13 - G14
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G14 - G16
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G16 - G17
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G17 - G18
Test H: No SCP Network Communication
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H1 - H3
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H4
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H5 - H6
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H6
I1 - I2
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I2 - I4
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Symptom Chart, Part 1
Symptom Chart, Part 2
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Module Communication Network: Testing and Inspection Module Configuration
Configurable Modules
The vehicle contains the following modules that are configurable:
^ Anti-lock Brake (ABS) module (if equipped)
^ Generic Electronic Module (GEM)
^ Remote Anti-theft Personality (RAP)/central security module (if equipped)
Initial Inspection
1. Visually inspect for obvious signs of electrical damage. Refer to the chart:
VISUAL INSPECTION CHART
Electrical ^
Wiring harness
^ Connectors
Programmable Parameters Index
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Module Communication Network: Service and Repair
Communication Circuit Wiring Repair
Heat Gun
SPECIAL TOOL(S)
1. Disconnect the battery ground cable.
2. Strip the wires.
3. Solder the wires.
1 Install the heat shrink tube.
2 Twist the wires together.
3 Solder the wires together.
NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder.
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4. Bend the wires back in a straight line.
NOTE: Wait for the solder to cool before moving the wires.
5. Position the (A) heat shrink tube over the (B) wire repair.
^ Overlap the heat shrink tube on both wires.
6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink
tube. 7. Reconnect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network
<--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment
Module Communication Network: Tools and Equipment
Special Tool(s)
Heat Gun
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network
<--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 4117
Module Communication Network: Tools and Equipment Diagnostic Special Service Tool(S)
Special Tool(s)
Worldwide Diagnostic System
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 4121
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 4122
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold.
3. Remove the KS.
1 Remove the bolt.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4126
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4127
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4128
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR LAMP (MIL)
Malfunction Indicator Lamp (MIL)
Check Engine, Service Engine Soon Or ISO Standard Engine Symbol
The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control
Module (PCM) has detected an OBD II emission-related component or system fault. When this
occurs, an OBD II Diagnostic Trouble Code (DTC) will be set.
^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or ISO standard engine symbol (Figure 16).
^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position.
^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster
proveout for approximately 4 seconds.
^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present.
- The instrument cluster will illuminate the MIL if the PCM does not send a control message to the
instrument cluster.
- The PCM is operating in the Hardware Limited Operation Strategy (HLOS).
- The MIL circuit is shorted to ground.
^ If the MIL remains off (during the bulb check): Bulb is damaged.
- MIL circuit is open.
^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three
consecutive drive cycles must be completed without a fault.
^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection.
^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist.
^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground
in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4136
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4137
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4138
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4139
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4140
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4141
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4142
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4143
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4144
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4145
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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Diagnosis > Page 4146
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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Diagnosis > Page 4147
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4148
4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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Diagnosis > Page 4149
The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4150
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4151
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions
Heated Oxygen Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4154
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4157
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4158
Circuit Identification Chart
System Codes Chart
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4159
Sample Diagrams
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4160
Sample Diagram
Sample Diagram
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4161
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4162
Circuit Identification Chart
SYSTEM CODES CHART
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4163
SAMPLE DIAGRAMS
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4164
Sample Diagram
Sample Diagram
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4165
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4166
Symbols
Symbols
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4167
Symbols
Symbols
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4168
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4169
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4170
Heated Oxygen Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4171
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4172
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4173
Heated Oxygen Sensor: Connector Views
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[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4174
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[Oxygen Sensor] > Component Information > Diagrams > Page 4175
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor Monitor
The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S
sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream
HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean
to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper
output voltage. The following illustration shows that input is required from the Engine Coolant
Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air
Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel
System Monitor and Misfire Detection Monitor must also have completed successfully before the
HO2S Monitor is enabled.
1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel
ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich
of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor
evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper
function.
2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response
frequency are checked. Excessive voltage is
determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A
fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S
heater circuit fault is determined by turning the heater on and off and looking for a corresponding
change in the Output State Monitor (OSM) and by measuring the current going through the heater
circuit. The HO2S Monitor DTCs can be categorized as follows:
The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130,
P1131, P1132, P1150, P1151 and P1152.
The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153.
The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151
and P0156.
The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and
P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in
on-demand is DTC P1127.
The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129.
3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive
drive cycles.
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4178
Heated Oxygen Sensor: Description and Operation PCM Inputs
HEATED OXYGEN SENSOR
Heated Oxygen Sensor (HO2S)
The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and
produces a variable voltage according to the amount of oxygen detected. A high concentration of
oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low
concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The
HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near
stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop
operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will
complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater
and heater control system are installed on some vehicles. The high power heater reaches closed
loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty
cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style
3.3 ohm heater.
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Heated Oxygen Sensor: Service and Repair
Socket, Exhaust Gas Oxygen Sensor
SPECIAL TOOL(S)
REMOVAL
1. Raise and support the vehicle. 2. Remove the Three Way Catalytic Converter (TWC).
3. Using the special tool, remove the HO2S.
NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S.
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[Oxygen Sensor] > Component Information > Description and Operation > Page 4180
Socket, Exhaust Gas Oxygen Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
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Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4189
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4190
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4191
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4192
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4193
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4199
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4200
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4201
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4202
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4203
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4208
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4209
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4210
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback
Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback
Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4216
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback
Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4217
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback
Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4218
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4219
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4220
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4221
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4222
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4223
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR).
1 Disconnect the electrical connector.
2 Disconnect the hoses.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
> Page 4233
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
> Page 4234
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
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> Page 4235
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
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Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's
Powertrain Control Module: Customer Interest Instrument Panel - `Buzz' At Low Engine RPM's
Article No. 01-4-10
03/05/01
NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD
AT IDLE OR LOW SPEED DRIVING
FORD: 2001 EXPLORER
ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a
"buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving
with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control
Module (PCM) resonating against the heat shield that is located inside the PCM.
ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the
following Service Procedure for details.
SERVICE PROCEDURE
1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section
303-14 for removal procedure.
2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following
dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the
Rotunda Squeak and Rattle Kit, part number 164-R4900.
3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the
top surface of the module at the rear center of the module. This will dampen the buzz noise from
the PCM outer case. (Figure 1).
4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure.
5. Test drive vehicle to verify that the noise is corrected.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 4240
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 702000, 702100, 702300
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
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Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures
Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
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a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 4252
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 4253
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
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25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel `Buzz' At Low Engine RPM's
Powertrain Control Module: All Technical Service Bulletins Instrument Panel - `Buzz' At Low
Engine RPM's
Article No. 01-4-10
03/05/01
NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD
AT IDLE OR LOW SPEED DRIVING
FORD: 2001 EXPLORER
ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a
"buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving
with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control
Module (PCM) resonating against the heat shield that is located inside the PCM.
ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the
following Service Procedure for details.
SERVICE PROCEDURE
1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section
303-14 for removal procedure.
2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following
dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the
Rotunda Squeak and Rattle Kit, part number 164-R4900.
3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the
top surface of the module at the rear center of the module. This will dampen the buzz noise from
the PCM outer case. (Figure 1).
4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure.
5. Test drive vehicle to verify that the noise is corrected.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel `Buzz' At Low Engine RPM's > Page 4259
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 702000, 702100, 702300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures
Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4265
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4266
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4267
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4268
Powertrain Control Module: Diagrams
Part 1
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4269
Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4270
Powertrain Control Module: Description and Operation
POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO)
The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem
generates vehicle speed information for distribution to the vehicle's electrical/electronic modules
and subsystems that require vehicle speed data. This subsystem senses the transmission output
shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired
signal or as a multiplexed data message.
The key features of the PCM-VSO system are to:
^ Infer vehicle movement from the output shaft sensor signal
^ Convert transmission output shaft rotational information to vehicle speed information
^ Compensate for tire size and axle ratio with a programmed calibration variable
^ Utilize a transfer case sensor for four wheel drive applications
^ Distribute vehicle speed information as a multiplexed message and/or an analog signal
The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft
Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is
sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per
mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into
the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing
changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information
can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM,
or by Speed and Odometer SCP multiplexed data messages.
The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT.
Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for
speed and distance data are transmitted as separate SCP messages over the SCP multiplex link.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
Repair > Flash Electrically Eraseable Programmable Read Only Memory
Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read
Only Memory
Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM
Description
Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an
Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the
vehicle strategy including calibration information specific to the vehicle and is capable of being
reprogrammed or reflashed repeatedly.
As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM as under Programming the VID Block for
a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block
not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can
also be tailored to accommodate various hardware changes made to the vehicle since production.
Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of
Acceptable Range. This is described under Making Changes to the VID Block and also under
Making Changes to the PCM Calibration. The VID block contains many items used by the strategy
for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane,
fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel
drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle
hardware and supported by the VID block will be displayed on the scan tool.
When changing items in the VID block, the strategy will place range limits on certain items such as
tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When
this limit is reached, the scan tool will display a message indicating the need to flash the PCM
again to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other
Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic
tool manufacturers users manual for details.
Programming the VID Block for a Replacement PCM
A new PCM will contain the latest strategy and calibration level for a particular vehicle. However,
the VID block will be blank and will need programming. There are two procedures available. The
first is an automatic data transfer from the old PCM to the new PCM and the second is manual data
entry into the new PCM.
Automatic data transfer will be performed if the old PCM is capable of communicating. This is done
by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The
stored data can now be downloaded to the new PCM after it has been replaced.
Manual data entry must be performed if the old module is damaged and is incapable of
communicating. Remove and replace the old PCM. You may be instructed to contact the "AS
BUILT" data center for the information needed to manually update the VID block with the scan tool.
Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M
technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed
World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or
"Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 4273
Powertrain Control Module: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the Powertrain Control Module (PCM) electrical connector.
3. Remove the nuts and the PCM cover.
4. Remove the PCM.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 4277
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 4278
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 4279
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation
Absolute Pressure Sensor: Description and Operation
THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR
Thermal Manifold Absolute Pressure (TMAP) Sensor
The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold
Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is
currently not being used. The MAP part of the sensor measures intake manifold air absolute
pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air
Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP)
sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced
into the intake manifold.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations > Page 4287
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations > Page 4288
Mass Air Flow Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations > Page 4289
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Locations > Page 4290
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Loosen the air cleaner outlet tube clamp and position the tube aside.
3. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4294
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4295
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4296
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 4300
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION SWITCH
Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches
The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch
pedal position and, in some manual transmission applications, both the clutch pedal engagement
position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference
Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP
signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed,
indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output
voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1
volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or
PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the
clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP
switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the
5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load
information in mass air flow and fuel calculations.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 4304
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 4305
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
2. Remove the retaining clip and the ECT sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4309
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4310
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4311
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Crankshaft Position (CKP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will
wear off after several engine revolutions.
^ Be sure the sensor wiring is routed away from the battery cable.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature Sensor > Page 4316
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions
Fuel Tank Pressure Sensor: Service Precautions
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
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Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure Sensor
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor
(Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles
equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank
pressure by forcing the system to purge.
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Fuel Tank Pressure Sensor: Service and Repair
REMOVAL
1. Remove the fuel tank.
2. Remove the fuel tank pressure sensor.
1 Disconnect the electrical connector.
2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the
fuel tank.
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
System Leak Test
^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
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Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE SENSOR
Intake Air Temperature (IAT)
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals
The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type
(Figure 37), are thermistor devices in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
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Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel spark and MAF.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above.
However, one is located before the supercharger at the air cleaner for standard OBD II/cold
weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control border-line spark and to help determine intercooler
efficiency.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams
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Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold.
3. Remove the KS.
1 Remove the bolt.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4337
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4338
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4339
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4340
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4341
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4342
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4343
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4344
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4345
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4346
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4347
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4348
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4349
4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4351
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Page 4352
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions
Heated Oxygen Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Diagram Information and Instructions > Page 4355
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Diagram Information and Instructions > Page 4356
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Diagram Information and Instructions > Page 4357
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Diagram Information and Instructions > Page 4358
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Diagram Information and Instructions > Page 4359
Circuit Identification Chart
System Codes Chart
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Diagram Information and Instructions > Page 4360
Sample Diagrams
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Diagram Information and Instructions > Page 4361
Sample Diagram
Sample Diagram
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Diagram Information and Instructions > Page 4362
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Diagram Information and Instructions > Page 4363
Circuit Identification Chart
SYSTEM CODES CHART
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Diagram Information and Instructions > Page 4364
SAMPLE DIAGRAMS
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Diagram Information and Instructions > Page 4365
Sample Diagram
Sample Diagram
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Diagram Information and Instructions > Page 4366
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Diagram Information and Instructions > Page 4367
Symbols
Symbols
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Diagram Information and Instructions > Page 4368
Symbols
Symbols
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Diagram Information and Instructions > Page 4369
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Diagram Information and Instructions > Page 4370
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Diagram Information and Instructions > Page 4371
Heated Oxygen Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Diagram Information and Instructions > Page 4372
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Diagram Information and Instructions > Page 4373
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Diagram Information and Instructions > Page 4374
Heated Oxygen Sensor: Connector Views
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Diagram Information and Instructions > Page 4375
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Page 4376
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description
and Operation > Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor Monitor
The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S
sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream
HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean
to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper
output voltage. The following illustration shows that input is required from the Engine Coolant
Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air
Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel
System Monitor and Misfire Detection Monitor must also have completed successfully before the
HO2S Monitor is enabled.
1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel
ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich
of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor
evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper
function.
2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response
frequency are checked. Excessive voltage is
determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A
fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S
heater circuit fault is determined by turning the heater on and off and looking for a corresponding
change in the Output State Monitor (OSM) and by measuring the current going through the heater
circuit. The HO2S Monitor DTCs can be categorized as follows:
The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130,
P1131, P1132, P1150, P1151 and P1152.
The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153.
The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151
and P0156.
The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and
P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in
on-demand is DTC P1127.
The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129.
3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive
drive cycles.
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and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 4379
Heated Oxygen Sensor: Description and Operation PCM Inputs
HEATED OXYGEN SENSOR
Heated Oxygen Sensor (HO2S)
The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and
produces a variable voltage according to the amount of oxygen detected. A high concentration of
oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low
concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The
HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near
stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop
operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will
complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater
and heater control system are installed on some vehicles. The high power heater reaches closed
loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty
cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style
3.3 ohm heater.
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and Operation > Page 4380
Heated Oxygen Sensor: Service and Repair
Socket, Exhaust Gas Oxygen Sensor
SPECIAL TOOL(S)
REMOVAL
1. Raise and support the vehicle. 2. Remove the Three Way Catalytic Converter (TWC).
3. Using the special tool, remove the HO2S.
NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S.
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and Operation > Page 4381
Socket, Exhaust Gas Oxygen Sensor
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4390
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4391
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4392
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4393
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4394
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4400
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4401
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4402
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4403
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4404
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4409
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4410
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4411
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4417
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4418
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4419
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4420
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4421
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4422
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4423
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4424
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR).
1 Disconnect the electrical connector.
2 Disconnect the hoses.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4428
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM
Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM
Inputs > Page 4431
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page
4432
Throttle Position Sensor: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Remove the Throttle Position (TP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts and the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4436
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4437
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4438
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4439
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4440
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor Bolt 98 - 115 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4444
Vehicle Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
Typical Vehicle Speed Sensor (VSS)
The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that
generates a waveform with a frequency that is proportional to the speed of the vehicle. If the
vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As
the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM
uses the frequency signal generated by the VSS (and other inputs) to control such parameters as
fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch
scheduling.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4445
Vehicle Speed Sensor: Service and Repair
Intermediate Shaft Speed (ISS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector.
3. Remove ISS sensor.
1. Remove the ISS sensor screw. 2. Remove the ISS sensor from the transmission.
^ Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the ISS sensor into the transmission. 2. Tighten ISS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4446
2. Connect ISS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 4450
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > PCM Inputs > Page 4453
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Page 4454
Throttle Position Sensor: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Remove the Throttle Position (TP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts and the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4458
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4459
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4460
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4461
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4462
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Variable Cam Timing System
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System
Variable Cam Timing System
Overview
The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine
speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the
exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the
combustion chamber. The residual gases cool the combustion chamber and are inert when mixed
with the incoming fresh charge of fuel and air. This results in better fuel economy and lower
Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas
Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature.
Variable Cam Timing
The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1)
on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT)
sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP)
sensor, Powertrain Control Module (PCM) (Figure 129).
1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature
(IAT) sensor, Engine Coolant
Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and
Crankshaft Position (CKP) sensor for determining the operating conditions of the engine.
2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are
met. The PCM disables the VCT system if
a fault is detected.
3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse
ring mounted on the exhaust camshaft.
Relative cam position is calculated by measuring the time between the rising edge of Profile
Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse.
4. The PCM continually calculates a cam position error value based on the difference between the
desired and actual position and a duty
cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit.
5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a
rotation motion from the helical mechanism in
the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve
to correct for cam position error.
Variable Cam Timing System
HARDWARE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Variable Cam Timing System > Page 4467
Variable Cam Timing (VCT) Solenoid Valve
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the
solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam
timing.
Variable Cam Timing Unit Assembly
Variable Cam Timing (VCT) Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Variable Cam Timing System > Page 4468
in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when
oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up
to 30 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Variable Cam Timing System > Page 4469
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit
Assembly
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum
overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The
camshaft is allowed to rotate up to 30 degrees.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Description and Operation
Variable Valve Timing Solenoid: Description and Operation
VARIABLE CAM TIMING (VCT) SOLENOID VALVE
Variable Cam Timing (VCT) Solenoid Valve
The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system.
The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the
PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or
retard the cam timing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor Bolt 98 - 115 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Specifications > Page 4476
Vehicle Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
Typical Vehicle Speed Sensor (VSS)
The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that
generates a waveform with a frequency that is proportional to the speed of the vehicle. If the
vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As
the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM
uses the frequency signal generated by the VSS (and other inputs) to control such parameters as
fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch
scheduling.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Specifications > Page 4477
Vehicle Speed Sensor: Service and Repair
Intermediate Shaft Speed (ISS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector.
3. Remove ISS sensor.
1. Remove the ISS sensor screw. 2. Remove the ISS sensor from the transmission.
^ Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the ISS sensor into the transmission. 2. Tighten ISS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Specifications > Page 4478
2. Connect ISS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Description and Operation
Air Diverter Solenoid: Description and Operation
AIR BYPASS SOLENOID
Secondary Air Injection Bypass Solenoid
The secondary air injection bypass (AIR bypass) solenoid (Figure 122) is used by the PCM to
control vacuum to the secondary air injection diverter (AIR diverter) valve. The AIR bypass solenoid
is a normally closed solenoid. The AIR bypass solenoid also has a filtered vent feature to permit
vacuum release.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation
Air Diverter Valve: Description and Operation
AIR DIVERTER VALVE
Air Injection Diverter (AIR Diverter) Valve
The secondary air injection diverter (AIR diverter) valve (Figure 123) is used with the electric AIR
pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the
electric AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral
check valve disk. When the electric AIR pump is off, and vacuum is removed from the AIR diverter
valve, the integral check valve disk is held on the seat and stops air from being drawn into the
exhaust system and prevents the back flow of the exhaust into the Secondary Air Injection System.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Description and Operation
Air Injection Pump: Description and Operation
ELECTRIC AIR PUMP
Electric Air Pump
The electric AIR pump (Figure 121) provides pressurized air to the Secondary Air Injection system.
The electric AIR pump functions independently of rpm and is controlled by the PCM. The electric
AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of
system backpressure and system voltage. The inlet system of the AIR pump incorporates a
non-serviceable filter and splash cap which helps to guard against dirt and water.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay
> Component Information > Description and Operation
Air Injection Pump Relay: Description and Operation
SOLID STATE RELAY
Solid State Relay
The solid state relay (Figure 124) switches the high current required for operation of the electric
AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve,
AIR > Component Information > Description and Operation
Vacuum Check Valve: Description and Operation
VACUUM CHECK VALVES
Vacuum Check Valve
A vacuum check valve (Figure 125) blocks air flow in one direction. It allows free air flow in the
other direction. The check side of this valve will hold the highest vacuum registered on the vacuum
side.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell
Technical Service Bulletin # 02-21-6 Date: 021028
Engine Controls/Emissions - Exhaust Sulfur Smell
Article No. 02-21-6
10/28/02
^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST
^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST
FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
Article 02-16-6 is being republished in its entirety to update the Service Procedure and model
years.
ISSUE
Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This
may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst
temperature, and amount of sulfur present in the fuel.
ACTION
Identify year, model, and build date to identify appropriate service procedure. For applications that
require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best
longevity, similar to what would commonly be used for exhaust heat shield rattle issues.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell > Page 4504
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Service Procedure
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.0L
Vehicles Built 1/14/02 Through 12/02/2002
At latest level for engine calibration.
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors heading for additional information.
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
Vehicles Built Before 1/14/02
1. Verify that WDS is at the latest level, B21.0 or higher.
2. Reprogram the PCM with the latest calibration.
3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
4. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
5. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE THE CONVERTER.
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.6L
Vehicles Built Prior To 12/02/2002
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell > Page 4505
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
2001-2002 2 DOOR EXPLORER SPORT 4.0L
7/24/00 Through 3/4/02 With 5R55E Transmission
1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the
old catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration only.
4. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L
Vehicles Built After 3/27/02
At latest level for engine calibration and converter, no service action will improve the situation.
1. See Contributing Factors Heading for additional information.
3/4/02 Through 3/27/02
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-AB only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L M5R4 MANUAL TRANSMISSION
11/2/01 Through 3/4/02 With Manual Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 SPORT TRAC 4.0L 5R55E TRANSMISSION
11/2/01 Through 3/4/02 With 5R55E Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration.
4. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell > Page 4506
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
DRIVE SEQUENCE AFTER REPAIRS COMPLETED
Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle.
Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for
this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the
transmission gear state. The goal of the drive procedure is to maintain a constant high temperature
level in the exhaust system through the use of increased engine speed. The combination of
increased temperature and driving will provide a sulfur cleaning environment for the catalyst
system.
CONTRIBUTING FACTORS TO SULFUR SMELL
Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the
amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the
sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer
sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get
hot enough to burn out stored sulfur residue and can produce a sulfur odor.
For example:
^ Extended Idle - Increase sulfur odor
^ Stop and go driving - Increase sulfur odor
^ Trailer Towing - Decrease sulfur odor
^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor
^ Abrupt accel/decel - Decrease sulfur odor
^ Hotter driving conditions - Decrease sulfur odor
^ Hilly terrain - Decrease sulfur odor
^ Canceling Overdrive - Decrease sulfur odor
Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to
the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate
year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different
fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries
supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor.
Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an
increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not
cause any durability or safety concerns with vehicle operation.
To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on
their vehicle as a result of the fuel and driving environment which creates a condition where sulfur
has been stored in their exhaust system. The service action performed allows the sulfur to pass
through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of
the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the
"rotten egg smell" to that of a "burning match". The odor will cease with time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell > Page 4507
PCM Calibration Information
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell > Page 4508
SUPERSEDES:02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 >
Engine Controls/Emissions - Exhaust Sulfur Smell
Technical Service Bulletin # 02-21-6 Date: 021028
Engine Controls/Emissions - Exhaust Sulfur Smell
Article No. 02-21-6
10/28/02
^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST
^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST
FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
Article 02-16-6 is being republished in its entirety to update the Service Procedure and model
years.
ISSUE
Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This
may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst
temperature, and amount of sulfur present in the fuel.
ACTION
Identify year, model, and build date to identify appropriate service procedure. For applications that
require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best
longevity, similar to what would commonly be used for exhaust heat shield rattle issues.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 >
Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4514
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Service Procedure
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.0L
Vehicles Built 1/14/02 Through 12/02/2002
At latest level for engine calibration.
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors heading for additional information.
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
Vehicles Built Before 1/14/02
1. Verify that WDS is at the latest level, B21.0 or higher.
2. Reprogram the PCM with the latest calibration.
3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
4. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
5. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE THE CONVERTER.
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.6L
Vehicles Built Prior To 12/02/2002
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 >
Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4515
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
2001-2002 2 DOOR EXPLORER SPORT 4.0L
7/24/00 Through 3/4/02 With 5R55E Transmission
1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the
old catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration only.
4. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L
Vehicles Built After 3/27/02
At latest level for engine calibration and converter, no service action will improve the situation.
1. See Contributing Factors Heading for additional information.
3/4/02 Through 3/27/02
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-AB only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L M5R4 MANUAL TRANSMISSION
11/2/01 Through 3/4/02 With Manual Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 SPORT TRAC 4.0L 5R55E TRANSMISSION
11/2/01 Through 3/4/02 With 5R55E Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration.
4. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 >
Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4516
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
DRIVE SEQUENCE AFTER REPAIRS COMPLETED
Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle.
Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for
this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the
transmission gear state. The goal of the drive procedure is to maintain a constant high temperature
level in the exhaust system through the use of increased engine speed. The combination of
increased temperature and driving will provide a sulfur cleaning environment for the catalyst
system.
CONTRIBUTING FACTORS TO SULFUR SMELL
Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the
amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the
sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer
sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get
hot enough to burn out stored sulfur residue and can produce a sulfur odor.
For example:
^ Extended Idle - Increase sulfur odor
^ Stop and go driving - Increase sulfur odor
^ Trailer Towing - Decrease sulfur odor
^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor
^ Abrupt accel/decel - Decrease sulfur odor
^ Hotter driving conditions - Decrease sulfur odor
^ Hilly terrain - Decrease sulfur odor
^ Canceling Overdrive - Decrease sulfur odor
Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to
the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate
year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different
fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries
supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor.
Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an
increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not
cause any durability or safety concerns with vehicle operation.
To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on
their vehicle as a result of the fuel and driving environment which creates a condition where sulfur
has been stored in their exhaust system. The service action performed allows the sulfur to pass
through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of
the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the
"rotten egg smell" to that of a "burning match". The odor will cease with time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 >
Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4517
PCM Calibration Information
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 >
Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4518
SUPERSEDES:02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4523
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4524
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4525
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4526
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4527
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4528
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4529
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4530
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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Emissions/Engine Controls - Driveability Diagnosis > Page 4551
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 4552
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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Emissions/Engine Controls - Driveability Diagnosis > Page 4554
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions
Catalytic Converter: Description and Operation Acronyms and Definitions
2V - L
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
2V: Two Valve engine configuration.
4V: Four Valve engine configuration.
ABS: Anti-lock Brake System.
A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by
cooling and dehydrating the air.
ACC: Air Conditioning Clutch. Indicates status of the A/C clutch.
ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch.
ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel.
ACP: Air Conditioning Head Pressure or A/C cycling switch input state.
ACPSW: Air Conditioning Pressure Switch.
ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module
(PCM) from the ACP switch or sensor.
ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout
control during heavy acceleration.
A/D: Analog-to-Digital. Analog-to-Digital signal conversion.
ADC: See ATDC.
AFCM: Alternative Fuel Control Module.
AIR: Secondary Air Injection.
AIRB: Secondary Air Injection Bypass.
Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system
when the electric air pump is commanded on.
AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System
has been evaluated for OBD (On-Board Diagnostic) II purposes.
Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry.
AIRM: Secondary AIR pump monitor.
Ambient Air Temperature: Temperature of the air surrounding an object.
Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits
of the signal.
ARB: Air Resource Board.
ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by
Speed Control Command Switch (SCCS) inputs.
ASCII: American Standard Code for Information Interchange.
ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke.
Measured in degrees of crankshaft rotation.
AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale,
rather than a digital display.
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AWD: All-Wheel Drive.
BARO: Barometric Pressure.
Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC
solenoid disconnected.
Base Timing: Spark advance in degrees before top dead center of the base engine without any
control from the PCM or ICM.
Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected
directly to the battery. Compare "Vehicle Power (VPWR)."
BAT TEMP: Battery Temperature.
BJB: Battery Junction Box.
BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness.
BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be
hydraulic or electric.
BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the
Brake Pedal Position (BPP) switch.
BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by
applying voltage to the control line.
BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its
stroke. Measured in degrees of crankshaft rotation.
Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to
module and to the DLC.
CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of
pressurized intake air.
CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which
govern fuel economy standards.
CANVNT: Canister Vent Solenoid.
Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine
exhaust emissions.
CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency
Monitor has successfully completed.
CCM: Comprehensive Component Monitor.
CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various
EEC components.
CD A through J: Coil Driver 1 through 10.
Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM)
and safety inspections.
CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case.
CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade.
CHTIL: Cylinder Head Temperature Indicator Lamp.
CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor
thermistor.
CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor.
CKP: Crankshaft Position. Senses the position of the crankshaft.
CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return.
CL: Closed Loop. An operating condition or mode which enables operation based on sensor
feedback.
CMP: Camshaft Position. Indicates camshaft position.
CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault.
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Information > Description and Operation > Acronyms and Definitions > Page 4561
CMS: Catalyst Monitor Sensor. Downstream H025.
CMVSS: Canadian Motor Vehicle Safety Standards.
CNG: Compressed Natural Gas.
CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust
emissions.
CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of
fuel.
Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to
increase voltage.
Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the
temperature of external and internal components stabilize.
CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs
generated during Continuous Memory Self-Test.
Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM
whenever the vehicle is operating.
CPP: Clutch Pedal Position. Indicates clutch pedal position.
CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the
clutch pedal is depressed.
CQIS: Common Quality Indicator System.
CSE GND: Case Ground.
CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to
obtain the air/fuel mixture appropriate for closed throttle operation.
CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer.
Data Communications Link: A communication path between various in-vehicle electronic modules.
Accessed by scan tools through the Data Link Connector (DLC).
DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage
measurement of ON time versus the full cycle period, expressed in percent.
DCL: Data Communication Link.
DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a
distributor.
Digital: Controls process information by switching the current or voltage ON and OFF.
DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information.
DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above
the valves.
DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument
cluster.
DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure
transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator
Valve.
DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other
unwanted deposits.
DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while
the vehicle is operating.
DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system.
DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the
On-Board Diagnostic System.
DVOM: Digital Volt-Ohm Meter.
E-85: Fuel containing 85% ethanol alcohol.
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EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an
electric air pump.
EAIRM: Electric Secondary Air Pump circuit Monitor.
ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade.
ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor
thermistor.
ECU: Electronic Control Unit. A module that handles the control strategy and monitors system
inputs or outputs.
EEC: Electronic Engine Control system.
EEC-V: Fifth generation EEC system.
EFT: Engine Fuel Temperature.
EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade.
EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor.
EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade.
EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor.
EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into
the combustion chamber.
EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the
monitor is complete.
EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to
operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control.
EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when
energized by the PCM.
EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is
threaded into the bottom of the intake plenum.
EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM.
EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the
EGR valve by varying the duty cycle to the regulator.
EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the
commanded output.
EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists
in the EGRV circuit.
EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module
(ICM) integrated into the PCM.
EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition
System.
EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System.
EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay
operation or noisy generator contacts.
EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new
vehicles perform to design specifications.
EPA: Environmental Protection Agency (U.S. Government).
EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that
requires the electronic storage of information.
ESOF: Electronic Shift-on-the-Fly.
EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere.
EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the
evaporative purge canister.
EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists
for the current commanded state.
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EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system
canister from atmospheric pressure during the EVAP OBD II Monitor test.
Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal
which absorbs and holds fuel vapors.
EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap
Canister Purge Solenoid by the PCM.
EVO: Electronic Variable Orifice.
EWP: Electric Water Pump.
Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed
sensor.
FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays
OFF, LOW, or HIGH status.
FC: Fan Control.
FCS: Fuel Control Solenoid.
FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed.
FEAD: Front End Accessory Drive.
FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming
Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming.
FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that
displays the % alcohol content in fuel.
FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating
the inferred alcohol content of fuel.
FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is
reliable or not. Displays a YES or NO.
FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse
width.
FFV: Flexible Fuel Vehicle.
FIFO: First In First Out.
FILO: First In Last Out.
FIM: Fuel Indicator Module.
FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as
a percentage.
FLIV: Fuel Level Input Voltage.
FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle
function in the event of a PCM or EEC component failure.
FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2.
Fuel Pump (Modulated). Fuel pump duty cycle percentage.
FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump.
FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit.
FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults.
Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time.
FRP: Fuel Rail Pressure. Based on FRP V.
FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure
Sensor.
FSC: Fail-Safe Cooling.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
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FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or
prevents Natural Gas flow to the fuel rail.
FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or
NO.
FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit.
FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts.
FTP V: Fuel Tank Pressure Voltage. From the FTP transducer.
FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump.
FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update.
FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1
(HEGO1).
FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2
(HEGO2).
FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP.
Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and
pressure from the fuel tank into the Evaporative Emission Control System.
FWD: Front Wheel Drive.
GEM: Generic Electronic Module.
GEN: Generator.
GENF: Generator Output Fault.
GENFDC: Generator Field Control Output.
GFS: Generator field signal monitor.
GND: Ground.
GPM: Grams Per Mile. Also known as Gallons Per Minute.
GPS: Global Positioning Satellite.
Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with
California on-board diagnostics.
GSS: Gear Select Solenoid.
GVW: Gross Vehicle Weight.
Hall Effect: A process where current is passed through a small slice of semi-conductor material and
a magnetic field to produce a small voltage in the semi-conductor.
Hard Fault: A fault currently present in the system.
HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2.
High Compression.
HCF: Hydraulic Cooling Fan.
HCFD: Hydraulic Cooling Fan Drive.
HFC: Hydraulic Cooling Fan.
HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit.
HFP: High Fuel Pump.
HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output
commands with fixed values in response to internal
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
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PCM malfunctions.
HO: High Output.
HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor.
Provides information on rich or lean exhaust conditions to the PCM.
Hot Soak: Period of time after an engine operates where localized combustion heat dissipates
throughout the engine.
HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the
HO2S sensor.
Hydrogen: Chemical symbol H. Highly flammable gas.
Hz: Hertz. Cycles per second.
IAC: Idle Air Control. Electrical control of throttle bypass air.
IAT: Intake Air Temperature.
IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor.
IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on
supercharged vehicles.
IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor.
IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit
functions.
ICM: Ignition Control Module. The module that controls the ignition system.
IFDM: Integrated Fuel Delivery Module.
IFS: Inertia Fuel Shutoff.
IGN GND: Ignition Ground.
Ignition: System used to provide high voltage spark for internal combustion engines.
IGNKEY(IGKY): Ignition Key status.
IGNSW (IGSW): Ignition Switch Position.
IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the
intake manifold.
IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults.
IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold.
INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output
from the PCM.
Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders.
Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion.
Intercooler: See CAC.
IPATS: Integrated Passive Anti-Theft System.
ISO: international Standards Organization.
KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even
when the vehicle is not operating.
KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM.
Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied
and the engine at rest.
Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the
engine running and the vehicle at rest.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4566
KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position.
Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the
combustion chamber of an engine.
KOEC: Key On Engine Continuous.
KOEO: Key On Engine off.
KOER: Key On Engine Running.
KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.).
KPH: Kilometers Per Hour.
KS: Knock Sensor. Detects engine knock.
L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts.
LEV: Low Emissions Vehicle.
LFC: Low Fan Control.
LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps.
LIFO: Last In First Out.
LILO: Last In Last Out.
LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM.
LOOP: indicates OPEN or CLOSED loop status.
LPG: Liquefied Petroleum Gas.
LPLR: Low Pressure Low Resistance fuel injector.
M-V
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
M-85: Fuel containing 85% methanol alcohol.
MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine.
MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor.
MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold.
MFC: Medium Fan Control.
MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled.
MFP: Modulated Fuel Pump.
Microprocessor: A digital processor on a chip which perform arithmetic and control logic.
MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related
malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON."
MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the
crankshaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
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MON: Motor Octane Number.
Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter.
MSOF: Manual Shift-on-the-Fly.
MY: Model Year.
NA: Naturally Aspirated. Engine that is not supercharged or turbocharged.
NAAO: North American Automotive Operations.
NC: Normally Closed.
NG: Natural Gas. A system capable of using natural gas for vehicle operation.
NGS: New Generation STAR (Self-Test Automatic Readout) tester.
NGVM: Natural Gas Vehicle Module.
NO: Norm ally Open.
NO(x): Oxides of Nitrogen. Formed at high combustion temperatures.
NVH: Noise, Vibration, Harshness. A classification of vehicle concerns.
OASIS: On-Line Automotive Service Information System.
OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that
monitors PCM input and output control signals.
On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM.
OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO.
OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane.
OEM: Original Equipment Manufacturer.
OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the
valves.
OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp
ON when engine oil temperature exceeds safe limits.
Open Circuit: A circuit which does not provide a complete path for flow of current.
OL: Open Loop. An operating condition based on instructions not modified by PCM feedback.
O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen
content in exhaust gasses.
OSC: Output State Control.
OSS: Output Shaft Speed.
Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to
ultraviolet radiation.
Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines.
PATS: Passive Anti-Theft System.
PATSIL: Passive Anti-Theft System Indicator Light.
PATSIN: Passive Anti-Theft System Receive Signal.
PATSOUT: Passive Anti-Theft System Transmit Signal.
PATSTRT: Passive Anti-Theft System Starter Relay Control
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4568
PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control)
Processor.
PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase
vapors into the combustion chamber.
PF: Purge Flow. Amount of fuel vapor burned in the engine.
Photochemical: Term describing the action of light on air pollutants which results in creating smog.
PID: Parameter Identifier. Identifies an address in PCM memory which contains operating
information.
Powertrain: Engine and transmission/transaxle components.
Pressure - Absolute: A pressure referenced to a perfect vacuum.
Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude.
Sometimes called Barometric Pressure.
Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer.
Pressure - Differential: The pressure difference between two regions, such as between the intake
manifold and atmospheric pressure.
Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric
pressure.
PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization.
Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP
Sensor).
PPM: Parts Per Million. A measure used in emission analysis.
PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions.
Protocol: A set of rules for the exchange of information on a network.
PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed
information.
PSP: Power Steering Pressure. Indicates the pressure in the power steering system.
PSP V: Power Steering Pressure Input Voltage.
PTEC: Powertrain Electronic Controller.
PTO: Power Take-Off.
PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized.
PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle.
PWR GND: Power Ground. The main ground circuit in the EEC system.
Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and
Continuous Memory Self-Tests. Results are displayed as a series of DTCs.
RABS: Rear Antilock Brake System.
RAM: Random Access Memory. Memory into which information can be written as well as read.
REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate
at high temperatures.
Regulator: Controls the alternator/generator field current to maintain proper battery charge.
Contained within the PCM in smart charging applications.
Relay: An electromechanical device in which connections in one circuit are opened or closed by
changes in another circuit.
REM: Rear Electronic Module.
Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to
improve idle quality and improve emissions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4569
RF: Radio Frequency.
RFI: Radio Frequency Interference.
RFS: Returnless Fuel System.
RM: Relay Module. A module containing two or more relays.
ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered.
RON: Research Octane Number.
Routine: A group of related tasks, such as a series of diagnostic tests.
RPM: Revolutions Per Minute.
RS: Reverse Switch.
RTN: Return. A dedicated sensor ground circuit.
RWD: Rear Wheel Drive.
SAE: Society of Automotive Engineers.
SBS: Supercharger Bypass Solenoid or its signal output from the PCM.
SC: Supercharged or Supercharger.
SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from
the supercharger wastegate actuator to allow for maximum boost.
SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger
Bypass circuit.
SCICP: Supercharger Intercooler Pump Control.
SCICPF: Supercharger Intercooler Pump Control Fault.
SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump.
SCP: Standard Corporate Protocol.
Self- Test: See Quick Test.
Sensor: A device that detects the value or change in a physical quantity, such as temperature,
pressure or flow rate, and converts the data into an electrical signal.
SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is
individually energized and timed relative to its cylinder intake event.
Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic
Interference (EMI).
Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that
intended.
SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input
during closed-loop operation.
SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors.
SIL: Shift Indicator Lamp.
Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output
circuit.
SME: Society of Manufacturing Engineers.
SOF: Shift-On-the-Fly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4570
SOHC: Single Overhead Cam.
Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and
pulled to a central position.
ST: Scan Tool. A device that interfaces with and communicates information on a data link.
Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7
parts of air for every 1 part of fuel.
Switch: A device for making, breaking, or changing the connections in an electrical circuit.
TA: Traction Assist.
TACH: Tachometer.
TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has
an air bypass channel around the throttle plate.
TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel
slippage. 2. Turbocharger.
TDC: Top Dead Center.
Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration.
Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors.
Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees
before (BTDC) or after (ATDC) top dead center of the compression stroke.
TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to
measure intake air temperature.
TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate
information for the PCM.
TP V: Throttle Position Sensor Voltage.
Transducer: A device that receives energy from one medium and transfers it to another. For
example, thermal energy is converted to an electrical signal through a temperature probe.
Transmissions/Transaxles:
NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the
end.
TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns,
procedures, or general service information.
Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles
while running. Also used during engine crank.
Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure.
Variable Reluctance: A process of passing a varying magnetic field through wire windings and
inducing a voltage.
VCT: Variable Camshaft Timing.
VECI: Vehicle Emission Control Information label.
VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced.
Includes information about the year, model, engine, and plant origin of the vehicle.
VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister.
VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a
digital (DVOM) display.
VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare
"Battery Voltage
VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as
a reference by certain sensors.
WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain
other operating conditions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4571
Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger.
WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body.
Zip Tube: Another name for "fresh air duct" or "air inlet duct".
TRANSMISSIONS:
NOTE: The transmission naming convention is as follows:
^ The first character, a number, is the number of forward gears.
^ The second character, either the letter "F" or "R," represents front (transaxle) or rear
(transmission) wheel drive.
^ The next set of characters, a grouping of numbers, represents the design torque capacity of the
transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle).
^ The last character, if used, is one of the following:
^ "E" for electronic shift
^ "N" for non-synchronous shift
^
"S" for synchronous shift
^ "W" for wide ratio
^ 4F27E: Also known as the FN Focus automatic transmission.
^ 4F44E: Formerly known as the CD4E.
^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E.
^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E.
^ 4R44E: Formerly known as A4LD for 3.0L applications.
^ 4R55E: Formerly known as A4LD for 4.0L applications.
^ 4R70W: Formerly known as AOD-E.
^ 4R100: Formerly known as E4OD.
^ 5R44E: Formerly known as A5LD for 3.0L applications.
^ 5R55E: Formerly known as A5LD for 4.0L applications.
^ 5R55N: Lincoln LS automatic transmission.
^ 5R55W: Wide-ratio truck transmission.
^ 4x4L: 4x4 Low.
^ A/T: Automatic Transmission.
^ CCS: Coast Clutch Solenoid.
^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists.
^ EPC: Electronic Pressure Control.
^ EPCV: Electronic Pressure Control Volts.
^ ESS: Electronic Shift Scheduling.
^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E.
^ M5OD: Manual 5-Speed transmission with overdrive (RWD).
^ M/T: Manual Transmission/Transaxle.
^ NPS: Neutral Pressure Switch or its signal input to the PCM.
^ OCS: Overdrive Cancel Switch.
^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft.
^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear
Switch (NGS), and Transmission Switch Neutral (TSN).
^ REVERSE or REV: Transmission Reverse Switch Input.
^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual
transmission/transaxle vehicles.
^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission.
^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and
disengagement of the Torque Converter Clutch.
^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS)
has been activated.
^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled
transmissions.
^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between
an engine and transmission/transaxle.
^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid.
^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same
case. Front-wheel drive applications.
^ Transmission: A device which selectively increases or decreases the ratio of relative rotation
between its input and output shafts. Rear-wheel drive applications.
^ TR: Transmission Range. The range in which the transmission is operating.
^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to
the PCM on the transmission range selector position.
^ TR V: Transmission Range Voltage.
^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft.
^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is
proportional to vehicle speed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4572
Catalytic Converter: Description and Operation Catalyst Efficiency Monitor - Federal Test
Procedure
Catalyst Efficiency Monitor - Federal Test Procedure
The Catalyst Efficiency Monitor uses an oxygen sensor before and after the catalyst to infer the
hydrocarbon efficiency based on oxygen storage capacity of the catalyst. Under normal, close-loop
fuel conditions, high efficiency catalysts have significant oxygen storage. This makes the switching
frequency of the rear Heated Oxygen Sensor (HO2S) very slow and reduces the amplitude of those
switches as compared to the switching frequency and amplitude of the front HO2S. As the catalyst
efficiency deteriorates, its ability to store oxygen declines. The post-catalyst or downstream HO2S
signal begins to switch more rapidly with increasing amplitude, approaching the switching
frequency and amplitude of the pre-catalyst or upstream HO2S.
All applications utilize an FTP-based (Federal Test Procedure) catalyst monitor. This simply means
that the catalyst monitor must run during a standard FTP emission test as opposed to the
20-second steady state catalyst monitor used in 1994 through some 1996 vehicles. Two slightly
different versions of the catalyst monitor are used in the 2001 model year.
Switch Ratio Method (1996 - 2001)
1. In order to assess catalyst oxygen storage, the monitor counts front and rear HO2S switches
during part-throttle, close-loop fuel condition after
the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are
accumulated in up to nine different air mass regions or cells although three air mass regions is
typical. Rear switches are counted in a single cell for all air mass regions. When the required
number of front switches has accumulated in each cell, the total number of rear switches is divided
by the total number of front switches to compute a switch ratio. A switch ratio near 0.0 indicates
high oxygen storage capacity, hence high HC efficiency. A switch ratio near 1.0 indicates low
oxygen storage capacity, hence low HC efficiency. If the actual switch ratio exceeds a calibrated
threshold switch ratio, the catalyst is considered failed.
Inputs from Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) (warm
engine), IAT (not extreme ambient temperatures), Mass Air Flow (MAF) (greater than minimum
engine load), Vehicle Speed Sensor (VSS) (within vehicle speed widow) and Throttle Position (TP)
(at part-throttle) are required to enable the Catalyst Efficiency Monitor.
2. The DTCs associated with this test are Diagnostic Trouble Code (DTC) P0420 (Bank 1) and
P0430 (Bank 2). Because an Exponentially
Weight Moving Average algorithm is use for malfunction determination, up to six driving cycles may
be required to illuminate the Malfunction Indicator Lamp (MIL) during normal customer driving. If
Keep Alive Memory (KAM) is reset, a malfunction will illuminate the MIL in 2 drive cycles.
Index Ratio Method (some 2001 and beyond)
1. In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches
during part-throttle, closed-loop fuel conditions
after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are
accumulated in up to three different air mass regions or cells. While catalyst monitoring entry
conditions are being met, the front and rear HO2S signal lengths are continually being calculated.
When the required number of front switches has accumulated in each cell, the total signal length of
the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index
ratio. An index ratio near 0.0 indicates high oxygen storage capacity, hence high efficiency. A
switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual
index ratio exceeds the threshold index ratio, the catalyst is considered failed.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4573
Inputs from ECT or CHT (warm engine), IAT (not extreme ambient temperatures), MAF (greater
than minimum engine load), VSS (within vehicle speed widow) and TP (at part-throttle) are required
to enable the Catalyst Efficiency Monitor.
2. The DTCs associated with this test are DTC P0420 (Bank 1) and P0430 (Bank 2). Because an
Exponentially Weighted Moving Average
algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate
the MIL during normal customer driving. If KAM is reset, a malfunction will illuminate the MIL in 2
drive cycles.
If the catalyst monitor does not complete during a particular driving cycle, the already accumulated
switch/signal data is retained in Keep Alive Memory and is used during the next driving cycle to
allow the catalyst monitor a better opportunity to complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4574
Catalytic Converter: Description and Operation Catalyst and Exhaust Systems
Catalyst and Exhaust System
Overview
The Catalytic Converter and Exhaust Systems (Figure 135) work together to control the release of
harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of
Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon
Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons
(HCs). CO, NO(x), and HCs are major air pollutants, and their emission into the atmosphere must
be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream
Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust
tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic
converter efficiency is monitored by the On Board Diagnostic (OBD II) system.
Generic Catalyst and Exhaust System
Catalytic Converter
A catalyst is a material that remains unchanged when it initiates and increases the speed of a
chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature.
The concentration of exhaust gas products released to the atmosphere must be controlled. The
catalytic converter assists in this task. It contains a catalyst in the form of a specially treated
honeycomb structure saturated with catalytically active precious metals. As the exhaust gases
come in contact with the catalyst, they are changed into mostly harmless products. The catalyst
initiates and speeds up heat producing chemical reactions of the exhaust gas components so they
are used up as much as possible.
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the
catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe
before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO),
unburned Hydrocarbons (HCs) and Oxides of Nitrogen (NO) in the exhaust emissions to an
acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a
muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly,
the exhaust emissions are directed to the atmosphere through an exhaust tailpipe.
HARDWARE
The downstream HO2S may be located after the light off catalyst or underbody catalyst. The
underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be
common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the
catalyst and exhaust system, refer to Exhaust System.
Three Way Catalytic Converter
The Three Way Catalytic (TWC) converter contains either platinum (Pt) and Rhodium (Rh) or
Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of
unburned HCs and CO and the reduction reaction of NO. The three-way conversion can be best
accomplished by always operating the engine air fuel/ratio at or close to stoichiometry.
Exhaust Manifold/Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of
cylinders.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4575
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
Upstream Heated and Downstream Heated Oxygen Sensors
The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas.
In addition to providing the PCM with indications of how rich/lean the engine is operating, the
upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is
an input to the Catalyst Efficiency monitor.
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine, and it also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4576
Catalytic Converter: Testing and Inspection
For information regarding diagnosis of this system refer to Computers and Control Systems
Diagnosis.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service and Repair > Catalytic Converter-Dual Three-Way
Catalytic Converter: Service and Repair Catalytic Converter-Dual Three-Way
Catalytic Converter-Dual Three-Way
Removal and Installation
1. Raise and support the vehicle.
2. Disconnect the catalyst monitor sensor.
3. Remove the bolts and springs.
4. Loosen the LH nuts.
5. Loosen the RH nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 4579
6. Remove the nuts.
7. Detach the dual three-way converter from the isolator and remove the converter.
8. Remove the gaskets and, if necessary, the catalyst monitor sensor.
^ Discard the gaskets.
9. CAUTION: Tighten the exhaust component fasteners starting from the rear of the vehicle.
NOTE: Make sure to apply anti-seize lubricant to the threads of the sensor prior to installation.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 4580
Catalytic Converter: Service and Repair Dual Converter Y-Pipe
Dual Converter Y-Pipe
Removal and Installation
1. Remove the dual three-way catalytic converter.
2. Disconnect the heated oxygen sensors.
3. Remove the LH nuts.
4. Remove the RH nuts and remove the dual converter Y-pipe.
5. Remove the converter inlet gasket and, necessary, the heated oxygen sensors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 4581
^ Discard the gasket.
6. CAUTION: Make sure that the dual converter Y-pipe to exhaust manifold nuts are tightened after
the three-way catalytic converter is installed.
NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4586
Canister Purge Control Valve: Service Precautions
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4587
Canister Purge Control Valve: Description and Operation
EVAP Canister Purge Valve
EVAP Canister Purge Valve
EVAP Canister Purge Valve
The EVAP canister purge valve (Figure 95) and (Figure 96) is the part of the Enhanced EVAP
system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the
EVAP canister to the intake manifold during various engine operating modes. The EVAP canister
purge valve is normally closed valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4588
Canister Purge Control Valve: Service and Repair
REMOVAL
1. Remove the battery tray.
2. Disconnect the tubes.
1 Disconnect the electrical connector.
2 Disconnect the tubes from the Evaporative Emission (EVAP) canister purge valve.
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
3. Disconnect the EVAP canister purge valve and bracket.
^ Remove the bolt.
4. Remove the EVAP canister purge valve.
1 Disconnect the vacuum line from the EVAP canister purge valve.
2 Remove the EVAP canister purge valve.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and
General Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. See: Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
Repair Verification Drive Cycle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service Precautions
Evaporative Canister Filter: Service Precautions
WARNING:
^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED
FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE
DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM
THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING,
POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE
PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service Precautions > Page 4592
Evaporative Canister Filter: Service and Repair
REMOVAL
1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
3. Disconnect the two chassis emissions lines from the evaporative emission tube.
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
4. Remove the evaporative emissions canister bolts.
5. Remove the evaporative emission canister with bracket assembly.
1 Disconnect the canister vent solenoid electrical connector.
2 Remove the EVAP canister with bracket assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service Precautions > Page 4593
6. Disconnect the canister vent solenoid hose assembly.
7. Remove the evaporative emission dust separator.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emission system. See: Testing and Inspection/Component Tests and
General Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. See: Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
Repair Verification Drive Cycle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Service Precautions
Evaporative Emission Control Canister: Service Precautions
WARNING:
^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED
FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE
DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM
THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING,
POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE
PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Service Precautions > Page 4597
Evaporative Emission Control Canister: Service and Repair
REMOVAL
1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
3. Disconnect the two chassis emissions lines from the evaporative emission tube.
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
4. Remove the evaporative emissions canister bolts.
5. Remove the evaporative emission canister with bracket assembly.
1 Disconnect the canister vent solenoid electrical connector.
2 Remove the EVAP canister with bracket assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Service Precautions > Page 4598
6. Remove the canister vent solenoid and the evaporative emission tube.
1 Disconnect the canister vent solenoid hose.
2 Remove the canister vent solenoid.
3 Remove the evaporative emission canister purge sleeve.
4 Remove the evaporative emission tube.
7. Remove the evaporative emission canister from the evaporative emission canister bracket.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and
General Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. See: Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
Repair Verification Drive Cycle
NOTE: Lubricate all O-ring seals with MERPOL(R) O-ring Seal Lubricant or equivalent meeting
Ford specification ESE-M99B144-B.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service Precautions
Evaporative Emissions Hose: Service Precautions
WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID
IS PRESENT IN THE AREA.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service Precautions > Page 4602
Evaporative Emissions Hose: Service and Repair
DISCONNECT
1. Disconnect the battery ground cable.
WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID
IS PRESENT IN THE AREA.
2. Disconnect the vapor tube from the fitting.
1 Squeeze the fitting.
2 Disconnect the vapor tube from the fitting.
CONNECT
1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions.
3. Push the tube into the fitting until it snaps in place.
4. Pull on the connection to make sure the fitting is secure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative System Service Port > Component Information > Service and Repair
Evaporative System Service Port: Service and Repair
REMOVAL
1. Remove the clip.
2. Disconnect the hoses.
3. Remove the test port assembly.
^ Disconnect the fitting.
^ Remove the test port assembly.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and
General Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. See: Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
Repair Verification Drive Cycle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Solenoid, Evaporative System > Component Information > Description and Operation
Leak Detection Solenoid: Description and Operation
Canister Vent Solenoid
Typical Canister Vent (CV) Solenoid
During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid (Figure 99) seals
the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain
the target vacuum in the fuel tank during the monitor run.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information
Leak Detection Valve: Technician Safety Information
WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID
IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information >
Page 4614
Leak Detection Valve: Vehicle Damage Warnings
CAUTION: The canister vent solenoid must not be energized for more than nine minutes at one
time. Once the canister vent solenoid is energized and de-energized, adequate time must be
allowed for the component to cool adequately. Failure to allow the component to cool may create a
false failure in the diagnostics, causing unnecessary repairs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Service Precautions > Page 4615
Leak Detection Valve: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID
IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
2. Remove the EVAP canister.
3. Remove the canister vent solenoid.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test the EVAP system. See: Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. See: Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
Repair Verification Drive Cycle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Service Precautions > Page 4616
Worldwide Diagnostic System
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Service Precautions
Liquid Vapor Separator: Service Precautions
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Service Precautions > Page 4620
Liquid Vapor Separator: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
2. Lower the fuel tank.
3. Remove the EVAP canister tube from the fuel vapor vent valve.
4. Remove the fuel vapor vent valve.
^ Press down and rotate the fuel vapor vent valve counterclockwise and remove it from the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and
General Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. See: Testing and
Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission
Repair Verification Drive Cycle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 4625
EGR Electronic Vacuum Regulator Solenoid: Description and Operation
EGR VACUUM REGULATOR SOLENOID
EGR Vacuum Regulator Solenoid
Test Graph
EGR Vacuum Regulator Solenoid Data Chart
The EGR vacuum regulator solenoid (Figure 88) is an electromagnetic device which is used to
regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically
controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the
vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed
to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no
electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not
enough to open the EGR valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 4626
EGR Electronic Vacuum Regulator Solenoid: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid.
1 Disconnect the electrical connector.
2 Disconnect the vacuum lines.
3 Remove the nut.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Description and Operation
EGR Tube: Description and Operation
ORIFICE TUBE ASSEMBLY
Orifice Tube Assembly
The orifice tube assembly (Figure 90) is a section of tubing connecting the exhaust system to the
intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also
contains the metering orifice and two pressure pick-up tubes. The internal metering orifice creates
a measurable pressure drop across it as the EGR valve opens and closes. This pressure
differential across the orifice is picked up by the differential pressure feedback EGR sensor which
provides feedback to the PCM.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Description and Operation > Page 4630
EGR Tube: Service and Repair
REMOVAL
1. Remove the lower Exhaust Gas Recirculation (EGR) valve tube.
1 Disconnect the tube fittings.
2 Disconnect the differential pressure feedback EGR hoses.
3 Remove the tube.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Differential Pressure Feedback EGR
EGR Valve: Description and Operation Differential Pressure Feedback EGR
EXHAUST GAS RECIRCULATION VALVE
EGR Valve
Test Graph
The EGR valve (Figure 89) in the Differential Pressure Feedback EGR system is a conventional,
vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas
recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the
valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring
force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg).
Since EGR flow requirement varies greatly, providing service specifications on flow rate is
impractical. The on-board diagnostic system monitors the EGR valve function and triggers a
Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured
directly as part of the field diagnostic procedures.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Differential Pressure Feedback EGR > Page 4635
EGR Valve: Description and Operation Electric Motor EGR System (EEGR)
ELECTRIC EGR VALVE
Electric EGR Motor/Valve Assembly
Electric EGR
The electric EGR valve (Figure 92) and (Figure 93) is a water cooled motor/valve assembly. The
motor is commanded to move in 52 discrete steps as it acts directly on the the EGR valve. The
position of the valve determines the rate of EGR. The built in spring works to close the valve
(against the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Differential Pressure Feedback EGR > Page 4636
motor opening force).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 4637
EGR Valve: Service and Repair
REMOVAL
1. Disconnect the Exhaust Gas Recirculation (EGR) valve.
^ Disconnect the vacuum line.
^ Disconnect the EGR valve tube fitting.
2. Remove the EGR valve bolts and the EGR valve.
^ Discard the gasket.
INSTALLATION
1. To install, reverse the removal procedure.
^ Carefully clean the EGR valve sealing surfaces.
^ Install a new EGR valve gasket.
NOTE: The EGR valve sealing surfaces are soft metals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4646
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4647
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4648
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4649
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4650
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4656
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4657
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4658
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4659
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4660
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4665
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4666
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4667
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4673
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4674
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4675
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4676
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4677
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4678
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4679
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4680
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR).
1 Disconnect the electrical connector.
2 Disconnect the hoses.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Service and Repair
Positive Crankcase Ventilation Valve: Service and Repair
REMOVAL
1. Remove the vacuum hose.
2. Remove the Positive Crankcase Ventilation (PCV) valve.
1 Disconnect the coolant hoses from the PCV valve.
2 Unlock and remove the PCV valve from the valve cover.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > Air Injection Pump Relay > Component Information > Description and Operation
Air Injection Pump Relay: Description and Operation
SOLID STATE RELAY
Solid State Relay
The solid state relay (Figure 124) switches the high current required for operation of the electric
AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4698
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4699
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4700
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4701
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4702
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4708
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4709
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4710
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4711
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4712
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4717
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4718
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4719
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4725
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4726
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4727
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4728
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4729
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4730
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4731
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4732
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR).
1 Disconnect the electrical connector.
2 Disconnect the hoses.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information > Page 4739
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 4740
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 4741
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the fuel injection supply manifold.
2. Remove the two bolts, the pressure relief valve and the O-ring seals.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions > Page 4745
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Disconnect the battery ground cable.
2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure.
This may drain fuel from the system. Drain the fuel
into a suitable container.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions > Page 4746
Fuel Pressure Gauge
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications > With Flexible Fuel
Idle Speed: Specifications With Flexible Fuel
With Automatic Transmission
Hot Idle ................................................................................................................................................
......................................................... 800 - 900 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
......................................................... 800 - 900 RPM
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications > With Flexible Fuel > Page 4751
Idle Speed: Specifications Without Flexible Fuel
With Automatic Transmission
Hot Idle ................................................................................................................................................
......................................................... 760 - 880 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
......................................................... 760 - 880 RPM
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 4755
Accelerator Pedal: Description and Operation
The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft
assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide
open throttle position. Hesitation or binding should not be experienced at any portion of the
accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator
and floor carpet must not contact the sliding inner member of the accelerator cable or interfere with
the accelerator pedal and shaft.
The acceleration control consists of an accelerator pedal and cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Accelerator Pedal: Initial Inspection and Diagnostic Overview
NOTE: Care should be exercised when carrying out repair on or around the accelerator pedal
linkage and controls.
1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which
would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may
cause binding. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed
specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for
excessive wear or damage.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4758
Accelerator Pedal: Symptom Related Diagnostic Procedures
Symptom Chart, Part 1
Symptom Chart, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Page 4759
Accelerator Pedal: Service and Repair
REMOVAL
1. Disconnect the cable from the accelerator pedal.
2. Remove the screw and the accelerator pedal.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the lower air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Locations > Page 4766
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Locations > Page 4767
Mass Air Flow Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Locations > Page 4768
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Locations > Page 4769
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Loosen the air cleaner outlet tube clamp and position the tube aside.
3. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle
Technical Service Bulletin # 03-3-5 Date: 030217
Engine Controls - No Start/Hard Start/Rough Idle
Article No. 03-3-5
02/17/03
DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS
FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 2000-2002 LS
MERCURY: 2000-2003 SABLE, MOUNTAINEER
ISSUE
Some vehicles, may exhibit drivability conditions.
These may include:
^ No start Difficult to start Stall
^ Low idle
^ Rough idle
^ High idle
^ Hesitation/surge while accelerating or at steady speed
These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction
Indicator Lamp (MIL). In some cases DTC and MIL may be evident.
ACTION
Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following
procedure is supplemental information to normal diagnostics to facilitate accurate identification of
malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling
problems, and Idle Speed Control System related DTC's.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4778
If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will
assist the technician making a correct repair the first time.
Perform normal diagnostics.
SERVICE INFORMATION
NOTE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4779
IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE
CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF
THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400,
698298
Disclaimer
IAC Diagnostic Service Tips - General
Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair
the drivability concern, but the long-term functionality of the valve is compromised.
For all drivability concerns, make certain the service writer obtains as much information as possible
from the customer as to the conditions causing drivability concern. Attached is a drivability concern
check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle.
NOTE
IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE
POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON
DECELERATION.
Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and
Lincoln LS.
1. Use the following conditions for the test described below:
^ Transmission in park
^ Engine temperature should be at least 190° F (88°C)
^ All accessories should be off steering wheel in the center position
^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system
^ Short and long term fuel trims less than 15%
^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission
Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the
chart in this TSB.
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure that there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird.
1. Use the following conditions for the test described below:
^ Transmission in park
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4780
^ Engine idle at approximately 650 RPM
^ Engine temperature should be at least 190° F (88° C)
^ All accessories and the engine cooling fan should be off
^ Steering wheel in the center position
^ EGRVR and EVAPDUTY CYCLE are zero
^ Short and long term fuel trims less than 15%
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
NOTE
IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650
RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER
THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND
CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM.
At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with
no purge flow (EVAPV duty cycle is 0%).
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
NOTE
IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY
CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER
DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN.
Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer,
Mountaineer, Explorer Sport and Explorer Sport Trac.
If no DTC's present check the following items in this order before examining the IAC valve:
^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB
^ Battery and fuse box power lead
^ Ground wire attachments
^ Wiring (wiggle test)
^ PCM voltage
^ Vacuum leaks
Examine AC valve under these conditions:
^ PCM updated to the latest available calibration
^ Transmission in park
^ Warm stabilized vehicle with engine temperature at least 190° F (88° C)
^ All accessories and cooling fan sh6uld be off
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4781
^ Steering wheel in the center position
^ EGVR and EVAPDC at zero, if the vehicle has an EGR system
^ Short and long term fuel trims (less than 15)
Perform the following steps in order:
1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3.
2. Allow vehicle to idle until the IACTRIM PID is 0.
NOTE
IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID
SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING
SHOULD BE TURNED OFF.
3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at
idle. The remainder of this TSB will help diagnose true root cause.
4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to
include the throttle body and air intake system) -is not operating properly.
NOTE
FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM
IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC.
IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns:
^ There are two primary causes of high idle:
1. Damaged IAC valves and
2. Vacuum leaks
^ AC valves can be damaged from engine induction backfires. Many times the customer may not
notice the induction backfire but will notice the high idle afterwards. Indications of valve damage
can be a shiny, almost polished appearance in the interior of the valve and a dislocated
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4782
pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1.
^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also
verify that the correct PCV valve is installed.
^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction
backfire can loosen or disconnect vacuum hoses.
^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear
normal in the service bay. If the duty cycle is below specification that is indicative that the engine is
receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to
restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS
(LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this
is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to
compensate.
IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle
Concerns:
^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on
the engine or obstruction in the air intake system could also reduce the engine RPMs.
^ There are four possible sources of friction load that can contribute to under speed error or low
idle concerns.
1. Power Steering Load
2. Air Conditioning Load
3. Electrical Load
4. Automatic Transmission Torque Converter Load
EAC Diagnostic Service Tips - Rough Idle
Concerns:
^ Rough idle concerns are often a result of a lean running condition
^ Another possible cause is contamination build up on the MAF sensor
EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start
^ While performing diagnostics, the technician should ensure that the fuel system is working
correctly for all engines with hard start/crank no-start complaints.
^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED
pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure
test:
^ Perform the KOEO fuel pressure test as specific in the PC/ED manual.
^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55
psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the
start of the test.
^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test.
^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible
after pump shut off, no more than 5 minutes after the start of the test.
NOTE
RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED
USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC.
IAC Diagnostic Service Tips - High Idle RPM at Start Up:
^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If
DTC 1506 is not present, this indicates that there is no fault present with the IAC.
^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast
idle (1600-2500 RPM that decreases slowly). No
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4783
repairs should be attempted because this is a normal temporary PCM calibration strategy to
prevent spark plug fouling during plant/transportation operation. The calibration will permanently
revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A
brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle
has been below 4 miles at a time.
IAC Diagnostic Service Tips - EAC Valve Noise Issues
For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire.
NOTE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4784
ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS
FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE
IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE
IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE,
COMPARE AGAINST A LIKE VEHICLE.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle
Technical Service Bulletin # 03-3-5 Date: 030217
Engine Controls - No Start/Hard Start/Rough Idle
Article No. 03-3-5
02/17/03
DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS
FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 2000-2002 LS
MERCURY: 2000-2003 SABLE, MOUNTAINEER
ISSUE
Some vehicles, may exhibit drivability conditions.
These may include:
^ No start Difficult to start Stall
^ Low idle
^ Rough idle
^ High idle
^ Hesitation/surge while accelerating or at steady speed
These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction
Indicator Lamp (MIL). In some cases DTC and MIL may be evident.
ACTION
Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following
procedure is supplemental information to normal diagnostics to facilitate accurate identification of
malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling
problems, and Idle Speed Control System related DTC's.
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4790
If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will
assist the technician making a correct repair the first time.
Perform normal diagnostics.
SERVICE INFORMATION
NOTE
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4791
IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE
CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF
THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400,
698298
Disclaimer
IAC Diagnostic Service Tips - General
Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair
the drivability concern, but the long-term functionality of the valve is compromised.
For all drivability concerns, make certain the service writer obtains as much information as possible
from the customer as to the conditions causing drivability concern. Attached is a drivability concern
check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle.
NOTE
IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE
POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON
DECELERATION.
Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and
Lincoln LS.
1. Use the following conditions for the test described below:
^ Transmission in park
^ Engine temperature should be at least 190° F (88°C)
^ All accessories should be off steering wheel in the center position
^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system
^ Short and long term fuel trims less than 15%
^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission
Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the
chart in this TSB.
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure that there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird.
1. Use the following conditions for the test described below:
^ Transmission in park
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^ Engine idle at approximately 650 RPM
^ Engine temperature should be at least 190° F (88° C)
^ All accessories and the engine cooling fan should be off
^ Steering wheel in the center position
^ EGRVR and EVAPDUTY CYCLE are zero
^ Short and long term fuel trims less than 15%
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
NOTE
IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650
RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER
THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND
CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM.
At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with
no purge flow (EVAPV duty cycle is 0%).
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
NOTE
IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY
CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER
DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN.
Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer,
Mountaineer, Explorer Sport and Explorer Sport Trac.
If no DTC's present check the following items in this order before examining the IAC valve:
^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB
^ Battery and fuse box power lead
^ Ground wire attachments
^ Wiring (wiggle test)
^ PCM voltage
^ Vacuum leaks
Examine AC valve under these conditions:
^ PCM updated to the latest available calibration
^ Transmission in park
^ Warm stabilized vehicle with engine temperature at least 190° F (88° C)
^ All accessories and cooling fan sh6uld be off
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4793
^ Steering wheel in the center position
^ EGVR and EVAPDC at zero, if the vehicle has an EGR system
^ Short and long term fuel trims (less than 15)
Perform the following steps in order:
1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3.
2. Allow vehicle to idle until the IACTRIM PID is 0.
NOTE
IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID
SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING
SHOULD BE TURNED OFF.
3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at
idle. The remainder of this TSB will help diagnose true root cause.
4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to
include the throttle body and air intake system) -is not operating properly.
NOTE
FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM
IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC.
IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns:
^ There are two primary causes of high idle:
1. Damaged IAC valves and
2. Vacuum leaks
^ AC valves can be damaged from engine induction backfires. Many times the customer may not
notice the induction backfire but will notice the high idle afterwards. Indications of valve damage
can be a shiny, almost polished appearance in the interior of the valve and a dislocated
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4794
pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1.
^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also
verify that the correct PCV valve is installed.
^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction
backfire can loosen or disconnect vacuum hoses.
^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear
normal in the service bay. If the duty cycle is below specification that is indicative that the engine is
receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to
restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS
(LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this
is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to
compensate.
IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle
Concerns:
^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on
the engine or obstruction in the air intake system could also reduce the engine RPMs.
^ There are four possible sources of friction load that can contribute to under speed error or low
idle concerns.
1. Power Steering Load
2. Air Conditioning Load
3. Electrical Load
4. Automatic Transmission Torque Converter Load
EAC Diagnostic Service Tips - Rough Idle
Concerns:
^ Rough idle concerns are often a result of a lean running condition
^ Another possible cause is contamination build up on the MAF sensor
EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start
^ While performing diagnostics, the technician should ensure that the fuel system is working
correctly for all engines with hard start/crank no-start complaints.
^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED
pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure
test:
^ Perform the KOEO fuel pressure test as specific in the PC/ED manual.
^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55
psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the
start of the test.
^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test.
^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible
after pump shut off, no more than 5 minutes after the start of the test.
NOTE
RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED
USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC.
IAC Diagnostic Service Tips - High Idle RPM at Start Up:
^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If
DTC 1506 is not present, this indicates that there is no fault present with the IAC.
^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast
idle (1600-2500 RPM that decreases slowly). No
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repairs should be attempted because this is a normal temporary PCM calibration strategy to
prevent spark plug fouling during plant/transportation operation. The calibration will permanently
revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A
brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle
has been below 4 miles at a time.
IAC Diagnostic Service Tips - EAC Valve Noise Issues
For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire.
NOTE
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4796
ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS
FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE
IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE
IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE,
COMPARE AGAINST A LIKE VEHICLE.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4805
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
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Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4806
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
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Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4807
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4808
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4809
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap
Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4815
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4816
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4817
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4818
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4819
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Page 4820
Fuel Filler Cap: Description and Operation
FUEL FILLER CAP
Fuel Filler Cap
The fuel filler cap (Figure 100) is used to prevent fuel spill and close the evaporative emission/fuel
system to atmosphere. Some vehicles may have a Fuel Cap Off Indicator Lamp (FCIL) in the
instrument cluster which will illuminate when there is a failure in the vapor management system
that may be due to the fuel filler cap not being sealed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 4825
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Disconnect the battery ground cable.
2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure.
This may drain fuel from the system. Drain the fuel
into a suitable container.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 4826
Fuel Pressure Gauge
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Service and Repair
Fuel Injector Wiring Harness: Service and Repair
REMOVAL
1. Remove the intake manifold.
2. Disconnect the six fuel injector electrical connectors.
NOTE: One connector is shown, the other five are similar.
3. Remove the bolt.
4. Disconnect the ignition coil electrical connector.
5. Disconnect the radio interference capacitor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Service and Repair > Page 4831
6. Disconnect the engine coolant temperature sensor electrical connector and the water
temperature indicator sender unit connector.
7. Disconnect the differential pressure feedback transducer electrical connector and the Camshaft
Position (CMP) sensor electrical connector. 8. Remove the drive belt tensioner.
9. Disconnect the generator wiring and position the wiring aside.
10. Remove the generator mounting bracket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Service and Repair > Page 4832
11. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
12. Remove the wiring anchors and position the wiring aside. 13. Raise and support the vehicle.
14. Disconnect the transmission portion of the wiring harness.
1 Disconnect the RH and LH Heated Oxygen Sensor (HO2S) connectors.
2 Disconnect the transmission control connector.
3 Disconnect the Output Shaft Speed (OSS) sensor connector.
4 Disconnect the digital Transmission Range (TR) sensor connector.
15. Disconnect the catalyst monitor sensor electrical connector. 16. Release the
transmission/transfer case portion of the wiring harness from any routing clips or pushpins. 17.
Route the transmission/transfer case portion of the wiring harness to the top of the engine. 18.
Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Service and Repair > Page 4833
19. Remove the wiring harness from the vehicle.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service Precautions
Fuel Line Coupler: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings
Fuel Line Coupler: Service and Repair Push Connect Fittings
Fuel Line Disconnect Tool
SPECIAL TOOL(S)
DISCONNECT
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Relieve the fuel pressure. See: Fuel Filter/Fuel Pressure Release
2. Disconnect the safety clip from the male hose.
3. Install the Fuel Line Disconnect Tool and push it into the fitting.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 4839
4. Separate the fittings.
^ Inspect for damage.
^ Clean the fittings.
CONNECT
1. Align the tube to the fitting and push until you hear a click.
2. Pull on the fitting to make sure it is fully engaged, then install the safety clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 4840
Fuel Line Coupler: Service and Repair R-Clip Fittings
DISCONNECT
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED.
CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
1. Relieve the fuel pressure. See: Fuel Filter/Fuel Pressure Release 2. Remove the shipping tab by
bending downward.
3. Spread the R-clip legs and push the clip into the fitting.
4. Separate the fitting from the tube.
CONNECT
1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat
of Super Premium SAE 5W-30 XO-5W30-QSP or equivalent meeting Ford specification
WSS-M2C153-G to the male tube
end.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 4841
3. Insert the R-clip into the fitting.
4. Align the tube and the fitting.
5. Insert the tube into the fitting and push together until a click is heard.
6. Pull on the connection to make sure it is fully engaged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 4842
Fuel Line Coupler: Service and Repair Spring Lock Couplings
Special Tool(s)
SPECIAL TOOL(S)
DISCONNECT
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Relieve the fuel pressure. See: Fuel Filter/Fuel Pressure Release
2. Remove the safety clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 4843
3. Install the Spring Lock Coupler Tool.
4. Close and push the Spring Lock Coupler Tool into the open side of the cage.
5. Separate the coupler.
6. Remove the Spring Lock Coupler Tool.
CONNECT
1. Inspect and clean both the coupling ends. Lubricate the O-ring seals with Super Premium SAE
5W-30 XO-5W30-QSP or equivalent meeting Ford
specification WSS-M2C153-G.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 4844
2. Connect the coupler by inserting the male end into the female end of the coupler. Push the
coupler together until the garter spring is engaged.
3. Pull on the coupler to make sure it is fully engaged.
4. Install the safety clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Page 4845
Fuel Line Coupler: Tools and Equipment
Special Tool(s)
Fuel Line Disconnect Tool
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations
Fuel Pressure Regulator: Locations
FUEL PUMP MODULE
Fuel Pump Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 4849
Fuel Pump Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 4850
Mechanical Returnless Fuel Pump Module (FPM)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 4851
Electronic Returnless Fuel Pump Module (FPM)
The Fuel Pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the
fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and
supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump
continuously refills the reservoir with fuel, and a check valve located in the manifold outlet
maintains system pressure when the fuel pump is not energized. A flapper valve located in the
bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial
fill.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 4852
Fuel Pressure Regulator: Description and Operation
FUEL PUMP MODULE
Fuel Pump Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 4853
Fuel Pump Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 4854
Mechanical Returnless Fuel Pump Module (FPM)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 4855
Electronic Returnless Fuel Pump Module (FPM)
The Fuel Pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the
fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and
supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump
continuously refills the reservoir with fuel, and a check valve located in the manifold outlet
maintains system pressure when the fuel pump is not energized. A flapper valve located in the
bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial
fill.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Description and Operation
Fuel Pressure Sensor/Switch: Description and Operation
FUEL RAIL PRESSURE SENSOR
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which
resistance changes with pressure. The electrical resistance of a strain gauge increases as
pressure increases, and decreases as pressure decreases. The varying resistance affects the
voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding
to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel
rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel
system. The differential fuel/intake manifold pressure together with measured fuel temperature
provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature
feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump
sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to
decrease.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Technician Safety Information > Page 4863
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Page 4864
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Page 4865
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the fuel injection supply manifold.
2. Remove the two bolts, the pressure relief valve and the O-ring seals.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Pulsation Damper: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Technician Safety Information > Page 4870
Fuel Pressure Pulsation Damper: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Page 4871
Fuel Pressure Pulsation Damper: Description and Operation
FUEL RAIL PULSE DAMPER
Pulse Damper
The fuel rail pulse damper (Figure 71) located on the fuel rail reduces fuel system noise caused by
the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold
vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse
damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail
pressure.)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Page 4872
Fuel Pressure Pulsation Damper: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the fuel injection supply manifold.
2. Remove the two bolts, the fuel pulse damper and the O-ring seals.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4879
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 4880
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 4881
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the fuel injection supply manifold.
2. Remove the two bolts, the pressure relief valve and the O-ring seals.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 4885
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 4886
Fuel Pump Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 4887
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Technician Safety Information
Fuel Rail: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Technician Safety Information > Page 4892
Fuel Rail: Vehicle Damage Warnings
CAUTION:
^ If the supply manifold is used as a leverage device, damage may occur to the supply manifold.
Care must be taken when working around the supply manifold.
^ Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can
cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4893
Fuel Rail: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply
manifold. Care must be taken when working around the supply manifold.
1. Remove the intake manifold. 2. Disconnect the fuel line.
3. Disconnect the six fuel injector electrical connectors.
NOTE: One connector is shown, the other five are similar.
4. Remove the four bolts from the fuel line.
5. Disconnect the fuel pulse damper vacuum hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4894
6. Remove the fuel injection supply manifold. 7. Remove the fuel injectors.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: ^
Lubricate the new O-ring seals with clean engine oil.
^ Use new fasteners to attach the fuel line.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Tools and Equipment
Fuel Supply Line: Tools and Equipment
3/8" Fuel Line Remover
AST tool# 8013
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Tools and Equipment > Page 4898
Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit.
- For R and R of Fuel and Feed Lines
- Quick line removal
- Gold-Anodized Aluminum Construction
- See Application Chart
- Included in the 8100, 8107 and #8110 Line Disconnect Sets.
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
This Tool is also available in the following kits:
8110 - 10-Pc. Line Disconnect Set
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Tools and Equipment > Page 4899
8107 - 7-Piece Line Disconnect Set
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4909
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4910
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4911
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4912
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4913
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap
Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4919
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4920
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4921
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4922
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4923
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Page 4924
Fuel Filler Hose: Service and Repair
REMOVAL
1. Remove the fuel tank filler cap.
NOTE: Fuel tank filler pipe may contain fuel.
2. Remove the screws.
3. Remove the fuel tank filler pipe and the vent hose from the fuel tank and remove the fuel tank
filler pipe.
INSTALLATION
1. Install the fuel tank filler pipe and the vent hose.
1 Orient the clamp bonding patch with the top of the fuel tank.
2 Tighten the hose clamps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Page 4925
2. Install the three fuel tank filler pipe screws.
3. Install the fuel tank filler cap.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4934
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4935
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4936
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4937
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4938
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap
Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4944
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4945
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4946
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4947
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4948
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair
Fuel Tank Mounting Straps: Service and Repair
REMOVAL
1. Raise and support the vehicle.
2. Use a suitable jack to support the fuel tank.
3. Remove the bolt and the fuel tank support strap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams
Fuel Tank Unit: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4958
Idle Air Control Valve: Description and Operation
IDLE AIR CONTROL VALVE
Nippondenso Idle Air Control (IAC) Valve Assembly
Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter
The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed
and provides a dashpot function. The IAC valve assembly meters intake air around the throttle
plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the
desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle.
The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The
PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the
desired rpm.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4959
Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors
On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount
of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low
speed and light load conditions.
NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED.
The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the
internal diode is measured in crossed terminal position with a digital multimeter, there will be an
incorrect or negative reading. It is important that the mating component and harness connectors
correctly oriented. Diagnostic procedures emphasize this importance.
The PCM uses the IAC valve assembly to control:
^ No touch start
^ Cold engine fast idle for rapid warm-up
^ Idle (corrects for engine load)
^ Stumble or stalling on deceleration (provides a dashpot function)
^ Over-temperature idle boost.
^ Air Assist to Injectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4960
Idle Air Control Valve: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Disconnect the electrical connector, and remove the bolts and the Idle Air Control (IAC) valve.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
Inertia Fuel Shutoff Switch
The Inertia Fuel Shutoff (IFS) switch is on the RH A-pillar lower trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 4964
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 4965
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump.
The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel
ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the
magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the
switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset
before restarting the vehicle. Refer to the Owner Guide for the location of the IFS.
Inertia Fuel Shutoff (IFS) Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 4966
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect
the electrical connector.
3. Remove the bolts and remove the IFS switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair
Intake Air Duct: Service and Repair
REMOVAL
1. Remove the engine appearance cover bolts.
2. Remove the air cleaner outlet tube.
1 Unclip the wire harness.
2 Disconnect the crankcase ventilation tube.
3 Loosen the air cleaner outlet tube clamps and remove the air cleaner outlet tube.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4973
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4974
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4975
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4980
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4981
Fuel Pump Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4982
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 4986
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 4987
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 4988
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations >
Page 4993
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations >
Page 4994
Mass Air Flow Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations >
Page 4995
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations >
Page 4996
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Loosen the air cleaner outlet tube clamp and position the tube aside.
3. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation
Fuel Pressure Sensor/Switch: Description and Operation
FUEL RAIL PRESSURE SENSOR
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which
resistance changes with pressure. The electrical resistance of a strain gauge increases as
pressure increases, and decreases as pressure decreases. The varying resistance affects the
voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding
to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel
rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel
system. The differential fuel/intake manifold pressure together with measured fuel temperature
provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature
feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump
sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to
decrease.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
Inertia Fuel Shutoff Switch
The Inertia Fuel Shutoff (IFS) switch is on the RH A-pillar lower trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5003
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5004
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump.
The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel
ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the
magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the
switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset
before restarting the vehicle. Refer to the Owner Guide for the location of the IFS.
Inertia Fuel Shutoff (IFS) Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5005
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect
the electrical connector.
3. Remove the bolts and remove the IFS switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5009
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs >
Page 5012
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 5013
Throttle Position Sensor: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Remove the Throttle Position (TP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts and the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Technician Safety Information
Throttle Body: Technician Safety Information
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Technician Safety Information > Page 5018
Throttle Body: Vehicle Damage Warnings
CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or
possible damage to the throttle body may occur.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body Housing
Throttle Body: Description and Operation Throttle Body Housing
THROTTLE BODY HOUSING
The throttle body housing assembly is a single piece of aluminum casting with an air passage and
a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed)
position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return
stop prevents the throttle plate from contacting the bore and sticking closed. The setting also
establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate
air flow, a special coating is applied to the throttle plate and bore to help seal this area. This
sealant/coating also makes the throttle body resistant to engine intake sludge accumulation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body Housing > Page 5021
Throttle Body: Description and Operation Throttle Body System Overview
THROTTLE BODY SYSTEM OVERVIEW
The throttle body system meters air to the engine during idle, part throttle, and Wide Open Throttle
(WOT) conditions. The throttle body system consists of an Idle Air Control (IAC) valve assembly,
idle air orifice, single or dual bores with butterfly valve throttle plates and a Throttle Position (TP)
sensor. One other source of idle air flow is the Positive Crankcase Ventilation (PCV) system. The
combined idle air flow (from idle air orifice IAC flow and PCV flow) is measured by the MAF sensor
on all applications.
During idle, the throttle body assembly provides a set amount of air flow to the engine through the
idle air passage and PCV valve. The IAC valve assembly provides additional air when commanded
by the Powertrain Control Module (PCM) to maintain the proper engine idle speed under varying
conditions. The IAC valve assembly mounts directly to the throttle body assembly in most
applications, but is remote-mounted to the intake manifold in some applications. Idle speed is
controlled by the PCM and cannot be adjusted.
NOTE: The traditional idle air adjust procedure as well as throttle return screw are no longer used
on OBD II applications.
Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle
plate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. Some
throttle body applications provide an air supply channel upstream of the throttle plate to provide
fresh air to the Positive Crankcase Ventilation (PCV) or IAC systems. Other throttle body
applications provide individual vacuum taps downstream of the throttle plate for PCV return,
Exhaust Gas Recirculation (EGR), Evaporative Emission (EVAP), and miscellaneous control
signals.
Throttle Body System Hardware
The major components of the throttle body assembly include the TP sensor, IAC valve assembly,
and throttle body housing assembly.
Throttle Position Sensor
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Idle Air Control Valve
Nippondenso Idle Air Control (IAC) Valve Assembly
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body Housing > Page 5022
Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter
The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed
and provides a dashpot function. The IAC valve assembly meters intake air around the throttle
plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the
desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle.
The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The
PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the
desired rpm.
Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors
On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount
of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low
speed and light load conditions.
NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED.
The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the
internal diode is measured in crossed terminal position with a digital multimeter, there will be an
incorrect or negative reading. It is important that the mating component and harness connectors
correctly oriented. Diagnostic procedures emphasize this importance.
The PCM uses the IAC valve assembly to control:
^ No touch start
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body Housing > Page 5023
^ Cold engine fast idle for rapid warm-up
^ Idle (corrects for engine load)
^ Stumble or stalling on deceleration (provides a dashpot function)
^ Over-temperature idle boost.
^ Air Assist to Injectors.
Throttle Body Housing
The throttle body housing assembly is a single piece of aluminum casting with an air passage and
a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed)
position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return
stop prevents the throttle plate from contacting the bore and sticking closed. The setting also
establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate
air flow, a special coating is applied to the throttle plate and bore to help seal this area. This
sealant/coating also makes the throttle body resistant to engine intake sludge accumulation.
Typical Attention Decal Locations
Features of the Throttle Body Assembly include:
1. Idle Air Control (IAC) valve assembly mounted directly to the throttle body assembly (some
vehicles). 2. A pre-set stop to locate the WOT position. 3. An air supply channel upstream of the
throttle plate to provide fresh air to the PCV system (some vehicles only). 4. Individual vacuum taps
for PCV, EGR, Evaporative Emission (EVAP) and miscellaneous control signals (some vehicles
only). 5. PCV air return (it applicable). 6. A throttle body-mounted Throttle Position (TP) sensor. 7.
A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to
engine intake sludge accumulation. These
throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal (Figure
116) advising not to clean.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Page 5024
Throttle Body: Service and Repair
REMOVAL
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or
possible damage to the throttle body may occur.
1. Remove the air cleaner outlet tube.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
3. Disconnect the accelerator cable and the speed control cable (if equipped).
4. Remove the throttle body.
^ Discard the gasket.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 5028
Throttle Cable/Linkage: Description and Operation
The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft
assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide
open throttle position. Hesitation or binding should not be experienced at any portion of the
accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator
and floor carpet must not contact the sliding inner member of the accelerator cable or interfere with
the accelerator pedal and shaft.
The acceleration control consists of an accelerator pedal and cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 5029
Throttle Cable/Linkage: Testing and Inspection
For further information regarding the diagnosis of this system, please refer to Accelerator Pedal;
Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 5030
Throttle Cable/Linkage: Service and Repair
REMOVAL
1. Disconnect the cable from the accelerator pedal.
2. Collapse the clips at the dash panel and push the cable through the dash panel into the engine
compartment.
3. Remove the bolts and the accelerator cable snow shield.
4. Disconnect the cable from the throttle body.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 5031
5. Remove the accelerator cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 5035
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > PCM Inputs > Page 5038
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Page 5039
Throttle Position Sensor: Service and Repair
REMOVAL
1. Remove the accelerator control snow shield.
2. Remove the Throttle Position (TP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts and the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Coil Terminal-To-Cylinder Relationship
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications > Page 5044
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 5052
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 5053
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 5054
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 5058
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 5059
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 5060
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Crankshaft Position (CKP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will
wear off after several engine revolutions.
^ Be sure the sensor wiring is routed away from the battery cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions
Ignition Cable: Service Precautions
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions > Page 5064
Ignition Cable: Service and Repair
Spark Plug Wire Remover
SPECIAL TOOL(S)
REMOVAL
1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug.
CAUTION: ^
Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the
ignition coil. 3. Disconnect the spark plug wires from the separators and remove the spark plug
wires.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the
exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of
the spark plug wire.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions > Page 5065
Spark Plug Wire Remover
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Mechanical Specifications
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5070
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5071
Ignition Coil: Service Precautions
CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible
damage to the spark plug wire.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5072
Ignition Coil: Description and Operation
Coil Pack
Horizontal Connector Six Tower Coil Pack
Series 5 Six Tower Coil Pack
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5073
Four - Tower Coil Packs
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5074
Series 5 Four Tower Coil Pack
Coil packs come in four tower, Series 5 four tower, six-tower horizontal connector and Series 5 Six
tower models. Two adjacent coil towers share a common coil and are called a matched pair. For
six-tower coil pack (six cylinder) applications the matched pairs are 1 and 5, 2 and 6, and 3 and 4
(Figure 56)and (Figure 57). For four-tower coil pack (four cylinder) applications the matched pairs
are 1 and 4, and 2 and 3 (Figure 58) and (Figure 59).
When the coil is fired by the PCM, spark is delivered through the matched pair towers to their
respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires
on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil
is fired the situation is reversed. The next pair of spark plugs fire according to the engine firing
order.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5075
Ignition Coil: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the ignition coil electrical connector.
3. Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible
damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
4. Remove the bolts and the ignition coil.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Page 5079
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Page 5080
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold.
3. Remove the KS.
1 Remove the bolt.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 5085
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 5086
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 5087
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 5091
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 5092
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 5093
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Remove the Crankshaft Position (CKP) sensor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will
wear off after several engine revolutions.
^ Be sure the sensor wiring is routed away from the battery cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder-Functional Lock Cylinder
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
3. To install, reverse the removal procedure.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
> Page 5099
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder
Removal and Installation
1. NOTE: Make sure the front wheels are in the straight-ahead position.
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and
instructions in the steering wheel
removal and installation procedure.
Remove the steering wheel assembly.
3. Twist off the cap from the ignition switch cylinder.
4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock
repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to
build the new lock cylinder to the current key code of the vehicle.
Remove the ignition switch lock cylinder. ^
Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch
lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the
steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
> Page 5100
5. Remove the bearing retainer.
6. Remove the bearing and gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
7. To install, reverse the removal procedure.
^ Install a new ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams > Page 5104
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams > Page 5105
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold.
3. Remove the KS.
1 Remove the bolt.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Spark Plug Gap
Spark Plug: Specifications Spark Plug Gap
Spark Plug Gap ...................................................................................................................................
.................................... 1.3-1.4 mm (0.052-0.056 in.)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Spark Plug Gap > Page 5110
Spark Plug: Specifications Spark Plug Torque
Spark Plug Torque ...............................................................................................................................
...................................................... 20 Nm (15 ft lbs)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 5111
Spark Plug: Application and ID
RH Original Spark Plug .......................................................................................................................
.............................................................. AGRF22PG LH Original Spark Plug .....................................
...................................................................................................................................................
AGRF22P New Spark Plug (Either Side) ............................................................................................
................................................................................. AGSF22PP
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 5112
Spark Plug: Service and Repair
REMOVAL
1. Remove the spark plug wires from the spark plugs.
2. Remove the spark plugs.
NOTE: ^
Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from.
New spark plugs can be used in any cylinder.
3. Inspect the spark plugs.
4. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 5119
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 5120
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 5121
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5124
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5125
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5126
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5127
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5128
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5129
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5130
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5131
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5132
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5133
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5134
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5135
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5136
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5137
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5138
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5139
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5140
Pressure Regulating Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5141
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5142
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5143
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 5144
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module (PCM) varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift
strategy.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 5145
Pressure Regulating Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Information > Diagrams > Page 5146
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 5147
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Information > Diagrams > Page 5148
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications
Shift Interlock Solenoid: Specifications
Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications > Page 5152
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Removal and Installation
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag Supplemental Restraint System (SRS) components and
before servicing, replacing, adjusting or striking components near the front or side air bag sensors,
such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please
refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at
or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery
ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped).
Disconnect the battery ground cable. Wait at least one minute before proceeding with the
procedure to allow the backup power supply to deplete its energy.
2. Remove the lower steering column opening finish panel.
1. Remove the screws and position the hood release handle out of the way. 2. Remove the two
screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining
clips and remove the lower steering column opening finish panel.
3. Remove the five bolts and the lower steering column opening finish panel reinforcement.
4. Remove the four nuts and lower the steering column.
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Specifications > Page 5153
5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering
column.
6. Disconnect the electrical connector and remove the insert plate and shift lock actuator.
7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary
to install a new clip for installation.
Remove and discard the clip.
8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications
Shift Solenoid: Specifications
Solenoid Clamp Screws 53 - 71 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > Page 5157
Shift Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > Page 5158
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > Page 5159
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > Page 5160
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5163
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Diagram Information and Instructions > Page 5164
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
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Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5166
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Diagram Information and Instructions > Page 5167
Circuit Identification Chart
System Codes Chart
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5168
Sample Diagrams
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Diagram Information and Instructions > Page 5169
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5170
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5171
Circuit Identification Chart
SYSTEM CODES CHART
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5172
SAMPLE DIAGRAMS
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Diagram Information and Instructions > Page 5173
Sample Diagram
Sample Diagram
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Diagram Information and Instructions > Page 5174
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Diagram Information and Instructions > Page 5175
Symbols
Symbols
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Diagram Information and Instructions > Page 5176
Symbols
Symbols
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Diagram Information and Instructions > Page 5177
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5178
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5179
Shift Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5180
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5181
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5182
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5183
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5184
Shift Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5185
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5186
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5187
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations
Torque Converter Clutch Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Page 5191
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Page 5192
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations > Page 5193
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Information > Diagrams > Diagram Information and Instructions > Page 5196
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5197
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5198
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5199
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5200
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5201
Sample Diagrams
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5202
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5203
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5204
Circuit Identification Chart
SYSTEM CODES CHART
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5205
SAMPLE DIAGRAMS
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5206
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5207
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5208
Symbols
Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 5209
Symbols
Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 5210
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Information > Diagrams > Diagram Information and Instructions > Page 5211
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Information > Diagrams > Diagram Information and Instructions > Page 5212
Torque Converter Clutch Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5213
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5214
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Information > Diagrams > Diagram Information and Instructions > Page 5215
Diagram 29-4
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Information > Diagrams > Page 5216
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
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Information > Diagrams > Page 5217
Torque Converter Clutch Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Information > Diagrams > Page 5218
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 5219
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 5220
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 5231
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 5232
Transmission Mode Switch: Service and Repair
Transmission Control Switch
Removal and Installation
1. Remove the Transmission Control Switch (TCS).
1. Remove the cover. 2. Remove the TCS.
2. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5236
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5237
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5238
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5239
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5240
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 5246
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 5247
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5250
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5251
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5252
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5253
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5254
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5255
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5256
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5257
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5258
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5259
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5260
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5261
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5262
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5263
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5264
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5265
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5266
Transmission Speed Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5267
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5268
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5269
Transmission Speed Sensor: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5270
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 5271
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 5272
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 5273
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5279
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5280
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5281
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5282
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5283
Circuit Identification Chart
System Codes Chart
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5284
Sample Diagrams
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5285
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5286
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5287
Circuit Identification Chart
SYSTEM CODES CHART
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5288
SAMPLE DIAGRAMS
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5289
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5290
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5291
Symbols
Symbols
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5292
Symbols
Symbols
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5293
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5294
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5295
Transmission Temperature Sensor/Switch: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5296
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5297
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5298
Diagram 29-4
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Page 5299
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
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Locations > Intermediate Shaft Speed Sensor
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 5306
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 5307
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Intermediate Shaft Speed Sensor
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Intermediate Shaft Speed Sensor > Page 5310
Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor
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Diagrams > Page 5311
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
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Diagrams > Page 5312
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
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Diagrams > Page 5313
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed
Turns
PROM - Programmable Read Only Memory: Customer Interest Steering - Shudder on Low Speed
Turns
TSB 05-17-15
09/05/05
STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified through the steering system. The
condition will vary according to ambient temperature, road surface friction, and steering wheel
turning speed.
ACTION As design changes have taken place in the steering system, it is important to note the
VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service
Procedure. Perform a thorough evacuation of air from the power steering system after
replacement/installation of parts.
SERVICE PROCEDURE
NOTE
BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT
INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM
FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL,
SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE
AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT
ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE
DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN
LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut
securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE
THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA
TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF
INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
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Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed
Turns > Page 5322
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO
STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT
DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to the Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
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Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed
Turns > Page 5323
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed
Turns > Page 5324
3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack
cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop
Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering
Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The
Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace
The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S
System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A,
3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And
Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A,
3504A9, 3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And
Purge The P/S System (Do Not
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed
Turns > Page 5325
Use With 3504A, 3504A9, 3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed
Turns or When Stopped
PROM - Programmable Read Only Memory: Customer Interest Steering - Shudder on Low Speed
Turns or When Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed
Turns or When Stopped > Page 5330
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed
Turns or When Stopped > Page 5331
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed
Turns or When Stopped > Page 5332
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed
Turns or When Stopped > Page 5333
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed
Turns or When Stopped > Page 5334
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed
Turns or When Stopped > Page 5335
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell
Technical Service Bulletin # 02-21-6 Date: 021028
Engine Controls/Emissions - Exhaust Sulfur Smell
Article No. 02-21-6
10/28/02
^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST
^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST
FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
Article 02-16-6 is being republished in its entirety to update the Service Procedure and model
years.
ISSUE
Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This
may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst
temperature, and amount of sulfur present in the fuel.
ACTION
Identify year, model, and build date to identify appropriate service procedure. For applications that
require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best
longevity, similar to what would commonly be used for exhaust heat shield rattle issues.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell > Page 5340
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Service Procedure
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.0L
Vehicles Built 1/14/02 Through 12/02/2002
At latest level for engine calibration.
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors heading for additional information.
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
Vehicles Built Before 1/14/02
1. Verify that WDS is at the latest level, B21.0 or higher.
2. Reprogram the PCM with the latest calibration.
3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
4. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
5. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE THE CONVERTER.
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.6L
Vehicles Built Prior To 12/02/2002
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell > Page 5341
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
2001-2002 2 DOOR EXPLORER SPORT 4.0L
7/24/00 Through 3/4/02 With 5R55E Transmission
1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the
old catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration only.
4. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L
Vehicles Built After 3/27/02
At latest level for engine calibration and converter, no service action will improve the situation.
1. See Contributing Factors Heading for additional information.
3/4/02 Through 3/27/02
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-AB only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L M5R4 MANUAL TRANSMISSION
11/2/01 Through 3/4/02 With Manual Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 SPORT TRAC 4.0L 5R55E TRANSMISSION
11/2/01 Through 3/4/02 With 5R55E Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration.
4. See Contributing Factors Heading for additional information.
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Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust
Sulfur Smell > Page 5342
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
DRIVE SEQUENCE AFTER REPAIRS COMPLETED
Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle.
Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for
this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the
transmission gear state. The goal of the drive procedure is to maintain a constant high temperature
level in the exhaust system through the use of increased engine speed. The combination of
increased temperature and driving will provide a sulfur cleaning environment for the catalyst
system.
CONTRIBUTING FACTORS TO SULFUR SMELL
Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the
amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the
sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer
sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get
hot enough to burn out stored sulfur residue and can produce a sulfur odor.
For example:
^ Extended Idle - Increase sulfur odor
^ Stop and go driving - Increase sulfur odor
^ Trailer Towing - Decrease sulfur odor
^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor
^ Abrupt accel/decel - Decrease sulfur odor
^ Hotter driving conditions - Decrease sulfur odor
^ Hilly terrain - Decrease sulfur odor
^ Canceling Overdrive - Decrease sulfur odor
Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to
the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate
year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different
fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries
supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor.
Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an
increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not
cause any durability or safety concerns with vehicle operation.
To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on
their vehicle as a result of the fuel and driving environment which creates a condition where sulfur
has been stored in their exhaust system. The service action performed allows the sulfur to pass
through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of
the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the
"rotten egg smell" to that of a "burning match". The odor will cease with time.
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PCM Calibration Information
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
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SUPERSEDES:02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
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05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns
PROM - Programmable Read Only Memory: All Technical Service Bulletins Steering - Shudder on
Low Speed Turns
TSB 05-17-15
09/05/05
STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified through the steering system. The
condition will vary according to ambient temperature, road surface friction, and steering wheel
turning speed.
ACTION As design changes have taken place in the steering system, it is important to note the
VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service
Procedure. Perform a thorough evacuation of air from the power steering system after
replacement/installation of parts.
SERVICE PROCEDURE
NOTE
BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT
INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM
FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL,
SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE
AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT
ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE
DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN
LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut
securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE
THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA
TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF
INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
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4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO
STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT
DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to the Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
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4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
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3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack
cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop
Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering
Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The
Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace
The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S
System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A,
3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And
Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A,
3504A9, 3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And
Purge The P/S System (Do Not
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05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5353
Use With 3504A, 3504A9, 3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
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04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
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03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped
PROM - Programmable Read Only Memory: All Technical Service Bulletins Steering - Shudder on
Low Speed Turns or When Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
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3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
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03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5365
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
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03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5366
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
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03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5367
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
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03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5368
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
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03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5369
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell
Technical Service Bulletin # 02-21-6 Date: 021028
Engine Controls/Emissions - Exhaust Sulfur Smell
Article No. 02-21-6
10/28/02
^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST
^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST
FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
Article 02-16-6 is being republished in its entirety to update the Service Procedure and model
years.
ISSUE
Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This
may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst
temperature, and amount of sulfur present in the fuel.
ACTION
Identify year, model, and build date to identify appropriate service procedure. For applications that
require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best
longevity, similar to what would commonly be used for exhaust heat shield rattle issues.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 5374
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Service Procedure
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.0L
Vehicles Built 1/14/02 Through 12/02/2002
At latest level for engine calibration.
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors heading for additional information.
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
Vehicles Built Before 1/14/02
1. Verify that WDS is at the latest level, B21.0 or higher.
2. Reprogram the PCM with the latest calibration.
3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
4. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
5. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE THE CONVERTER.
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.6L
Vehicles Built Prior To 12/02/2002
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to
the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors Heading for additional information.
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02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 5375
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
2001-2002 2 DOOR EXPLORER SPORT 4.0L
7/24/00 Through 3/4/02 With 5R55E Transmission
1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the
old catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration only.
4. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L
Vehicles Built After 3/27/02
At latest level for engine calibration and converter, no service action will improve the situation.
1. See Contributing Factors Heading for additional information.
3/4/02 Through 3/27/02
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-AB only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L M5R4 MANUAL TRANSMISSION
11/2/01 Through 3/4/02 With Manual Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 SPORT TRAC 4.0L 5R55E TRANSMISSION
11/2/01 Through 3/4/02 With 5R55E Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old
catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration.
4. See Contributing Factors Heading for additional information.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
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02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 5376
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
DRIVE SEQUENCE AFTER REPAIRS COMPLETED
Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle.
Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for
this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the
transmission gear state. The goal of the drive procedure is to maintain a constant high temperature
level in the exhaust system through the use of increased engine speed. The combination of
increased temperature and driving will provide a sulfur cleaning environment for the catalyst
system.
CONTRIBUTING FACTORS TO SULFUR SMELL
Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the
amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the
sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer
sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get
hot enough to burn out stored sulfur residue and can produce a sulfur odor.
For example:
^ Extended Idle - Increase sulfur odor
^ Stop and go driving - Increase sulfur odor
^ Trailer Towing - Decrease sulfur odor
^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor
^ Abrupt accel/decel - Decrease sulfur odor
^ Hotter driving conditions - Decrease sulfur odor
^ Hilly terrain - Decrease sulfur odor
^ Canceling Overdrive - Decrease sulfur odor
Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to
the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate
year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different
fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries
supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor.
Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an
increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not
cause any durability or safety concerns with vehicle operation.
To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on
their vehicle as a result of the fuel and driving environment which creates a condition where sulfur
has been stored in their exhaust system. The service action performed allows the sulfur to pass
through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of
the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the
"rotten egg smell" to that of a "burning match". The odor will cease with time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 5377
PCM Calibration Information
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 5378
SUPERSEDES:02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through
12-02-02, 4.6L Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003
Explorer/Mountaineer 4.0L Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built
7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic
Transmission, 11-02-01 Through 3-4-02 With Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5384
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5385
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5392
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5393
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5394
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5397
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5398
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5399
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5400
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5401
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5402
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5403
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5404
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5405
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5406
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5407
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5408
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5409
Symbols
Symbols
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5410
Symbols
Symbols
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5411
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5412
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5413
Pressure Regulating Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5414
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5415
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5416
Diagram 29-4
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5417
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module (PCM) varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift
strategy.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5418
Pressure Regulating Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5419
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5420
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5421
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications
Shift Interlock Solenoid: Specifications
Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5425
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Removal and Installation
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag Supplemental Restraint System (SRS) components and
before servicing, replacing, adjusting or striking components near the front or side air bag sensors,
such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please
refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at
or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery
ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped).
Disconnect the battery ground cable. Wait at least one minute before proceeding with the
procedure to allow the backup power supply to deplete its energy.
2. Remove the lower steering column opening finish panel.
1. Remove the screws and position the hood release handle out of the way. 2. Remove the two
screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining
clips and remove the lower steering column opening finish panel.
3. Remove the five bolts and the lower steering column opening finish panel reinforcement.
4. Remove the four nuts and lower the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5426
5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering
column.
6. Disconnect the electrical connector and remove the insert plate and shift lock actuator.
7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary
to install a new clip for installation.
Remove and discard the clip.
8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications
Shift Solenoid: Specifications
Solenoid Clamp Screws 53 - 71 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5430
Shift Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5431
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5432
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5433
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Shift Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5436
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5437
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5438
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5439
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5440
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5441
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5442
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5443
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5444
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5445
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5446
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5447
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5448
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5449
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5450
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5451
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5452
Shift Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5453
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5454
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5455
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5456
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5457
Shift Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5458
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5459
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5460
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations
Torque Converter Clutch Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5464
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5465
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5466
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5469
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5470
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5471
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5472
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5473
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5474
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5475
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5476
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5477
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5478
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5479
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5480
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5481
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5482
Symbols
Symbols
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5483
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5484
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5485
Torque Converter Clutch Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5486
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5487
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5488
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5489
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5490
Torque Converter Clutch Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5491
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5492
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5493
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5499
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5500
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5501
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5504
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5505
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5506
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5507
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5508
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5509
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5510
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5511
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5512
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5513
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5514
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5515
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5516
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5517
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5518
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5519
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5520
Pressure Regulating Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5521
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5522
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5523
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5524
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module (PCM) varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift
strategy.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5525
Pressure Regulating Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5526
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5527
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5528
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications
Shift Interlock Solenoid: Specifications
Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5532
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Removal and Installation
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag Supplemental Restraint System (SRS) components and
before servicing, replacing, adjusting or striking components near the front or side air bag sensors,
such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please
refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at
or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery
ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped).
Disconnect the battery ground cable. Wait at least one minute before proceeding with the
procedure to allow the backup power supply to deplete its energy.
2. Remove the lower steering column opening finish panel.
1. Remove the screws and position the hood release handle out of the way. 2. Remove the two
screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining
clips and remove the lower steering column opening finish panel.
3. Remove the five bolts and the lower steering column opening finish panel reinforcement.
4. Remove the four nuts and lower the steering column.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5533
5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering
column.
6. Disconnect the electrical connector and remove the insert plate and shift lock actuator.
7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary
to install a new clip for installation.
Remove and discard the clip.
8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications
Shift Solenoid: Specifications
Solenoid Clamp Screws 53 - 71 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5537
Shift Solenoid: Locations
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Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5539
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5540
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5543
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5544
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5545
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5546
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5547
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5548
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5549
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5550
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5551
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5552
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5553
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5554
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5555
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5556
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5557
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5558
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5559
Shift Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5560
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5561
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5562
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5563
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5564
Shift Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5565
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5566
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5567
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations
Torque Converter Clutch Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5571
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5572
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5573
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5576
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5577
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5578
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5579
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5580
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5581
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5582
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5583
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5584
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5585
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5586
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5587
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5588
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5589
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5590
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5591
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5592
Torque Converter Clutch Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5593
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5594
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5595
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5596
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5597
Torque Converter Clutch Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5598
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5599
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5600
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T
- 5R44E/5R55E Fluid Leak at Servo Cover
Band Apply Servo: Customer Interest A/T - 5R44E/5R55E Fluid Leak at Servo Cover
Article No. 02-8-3
04/29/02
TRANSMISSION - 5R44E OR 5R55E - FLUID LEAK AT
SERVO COVER - VEHICLES PRODUCED 6/1/2001 THROUGH 3/31/2002 EQUIPPED WITH
2.3L, 3.0L OR 4.0L ENGINES
FORD: 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER
ISSUE Some vehicles equipped with a 2.3L, 3.0L or 4.0L engine and 5R44E or 5R55E automatic
transmission, produced 6/1/2001 through 3/31/02, operating in cold climates, may exhibit a fluid
leak at the transmission Servo Cover(s). This, may be caused by the Servo Cover.
ACTION Verify the condition. If the condition exists, the Servo Cover(s) may need to be replaced
with new cover(s) (Figure 1). Check the transmission fluid level and fluid condition. If fluid is just
low and the fluid condition is not burnt, refer to the following Service Procedure to replace the
Servo Cover(s). If the transmission shows evidence of damage due to no fluid, no engagements or
severely burnt fluid, the transmission may need additional repair or replacement. Follow normal
repair or replacement procedures when servicing anything other than the Servo Cover(s).
SERVICE PROCEDURE
Service Procedure for replacing the Front or Intermediate Servo Cover:
NOTE
AN IN-LINE FLUID FILTER OR AN IN-LINE FLUID FILTER KIT IS NOT REQUIRED FOR THIS
PROCEDURE.
1. Remove the catalytic converter.
2. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve
Body", Section 307-01, remove the Main Control assembly.
NOTE
DO NOT ALLOW THE BAND ADJUSTMENT SCREW TO BACK OUT COMPLETELY OR THE
BAND STRUT WILL FALL OUT OF POSITION.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T
- 5R44E/5R55E Fluid Leak at Servo Cover > Page 5609
3. Remove and discard the band lock nut, then back out the adjusting screw three to four turns.
4. Install special service tool 307-340 (T95L-77028-A).
5. Tighten special tool to compress the servo spring.
CAUTION
THE SERVO COVER IS UNDER SPRING TENSION.
6. Remove the Servo Cover retaining ring.
7. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor.
NOTE
DO NOT ALLOW THE PISTON TO COME OUT OF THE BORE.
8. Tap lightly on the cover, then remove the cover.
NOTE
DO NOT DAMAGE THE COVER SEALS DURING INSTALLATION. DO NOT PRESS SERVO
COVER AND SEALS PAST THE RELIEF HOLE IN THE CASE OR SEALS MAY BE DAMAGED.
9. Lubricate Servo Cover Seal and install a new Servo Cover Assembly onto the piston and into the
piston bore Refer to the Servo Cover Application Chart for Servo Cover applications.
10. Install special service tool 307-340 (T95L-77028-A).
11. Tighten special tool to compress the Servo Cover and spring.
12. Install retaining ring.
13. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. Clean
residual fluid from Servo Cover area.
NOTE
INSTALL, BUT DO NOT TIGHTEN, A NEW LOCK NUT ON THE SCREW.
NOTE
THE WRENCH WILL CLICK AT THE SPECIFIED TORQUE.
NOTE
IF REPLACING BOTH SERVO COVERS, ORDER TWO (2) NEW LOCK NUTS.
14. Apply petroleum jelly to the lock nut seal. Install new locknut, but do not tighten at this time.
Using special service tool 307-S022, tighten the band adjusting screw to 14 N.m (10 Lb-ft), then
back oft the adjusting screw exactly two (2) turns and hold that position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T
- 5R44E/5R55E Fluid Leak at Servo Cover > Page 5610
15. Hold the band adjusting screw stationary and tighten the band locknut to 47-61 N.m (35-44
lb-ft).
16. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve
Body", Section 307-01, Install the Main Control assembly.
17. Reinstall the catalytic converter.
Parts Block
OTHER APPLICABLE ARTICLES: 02-8-2
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7L173 01
OASIS CODES: 504000, 510000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr
> 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover
Band Apply Servo: All Technical Service Bulletins A/T - 5R44E/5R55E Fluid Leak at Servo Cover
Article No. 02-8-3
04/29/02
TRANSMISSION - 5R44E OR 5R55E - FLUID LEAK AT
SERVO COVER - VEHICLES PRODUCED 6/1/2001 THROUGH 3/31/2002 EQUIPPED WITH
2.3L, 3.0L OR 4.0L ENGINES
FORD: 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER
ISSUE Some vehicles equipped with a 2.3L, 3.0L or 4.0L engine and 5R44E or 5R55E automatic
transmission, produced 6/1/2001 through 3/31/02, operating in cold climates, may exhibit a fluid
leak at the transmission Servo Cover(s). This, may be caused by the Servo Cover.
ACTION Verify the condition. If the condition exists, the Servo Cover(s) may need to be replaced
with new cover(s) (Figure 1). Check the transmission fluid level and fluid condition. If fluid is just
low and the fluid condition is not burnt, refer to the following Service Procedure to replace the
Servo Cover(s). If the transmission shows evidence of damage due to no fluid, no engagements or
severely burnt fluid, the transmission may need additional repair or replacement. Follow normal
repair or replacement procedures when servicing anything other than the Servo Cover(s).
SERVICE PROCEDURE
Service Procedure for replacing the Front or Intermediate Servo Cover:
NOTE
AN IN-LINE FLUID FILTER OR AN IN-LINE FLUID FILTER KIT IS NOT REQUIRED FOR THIS
PROCEDURE.
1. Remove the catalytic converter.
2. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve
Body", Section 307-01, remove the Main Control assembly.
NOTE
DO NOT ALLOW THE BAND ADJUSTMENT SCREW TO BACK OUT COMPLETELY OR THE
BAND STRUT WILL FALL OUT OF POSITION.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr
> 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5616
3. Remove and discard the band lock nut, then back out the adjusting screw three to four turns.
4. Install special service tool 307-340 (T95L-77028-A).
5. Tighten special tool to compress the servo spring.
CAUTION
THE SERVO COVER IS UNDER SPRING TENSION.
6. Remove the Servo Cover retaining ring.
7. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor.
NOTE
DO NOT ALLOW THE PISTON TO COME OUT OF THE BORE.
8. Tap lightly on the cover, then remove the cover.
NOTE
DO NOT DAMAGE THE COVER SEALS DURING INSTALLATION. DO NOT PRESS SERVO
COVER AND SEALS PAST THE RELIEF HOLE IN THE CASE OR SEALS MAY BE DAMAGED.
9. Lubricate Servo Cover Seal and install a new Servo Cover Assembly onto the piston and into the
piston bore Refer to the Servo Cover Application Chart for Servo Cover applications.
10. Install special service tool 307-340 (T95L-77028-A).
11. Tighten special tool to compress the Servo Cover and spring.
12. Install retaining ring.
13. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. Clean
residual fluid from Servo Cover area.
NOTE
INSTALL, BUT DO NOT TIGHTEN, A NEW LOCK NUT ON THE SCREW.
NOTE
THE WRENCH WILL CLICK AT THE SPECIFIED TORQUE.
NOTE
IF REPLACING BOTH SERVO COVERS, ORDER TWO (2) NEW LOCK NUTS.
14. Apply petroleum jelly to the lock nut seal. Install new locknut, but do not tighten at this time.
Using special service tool 307-S022, tighten the band adjusting screw to 14 N.m (10 Lb-ft), then
back oft the adjusting screw exactly two (2) turns and hold that position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr
> 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5617
15. Hold the band adjusting screw stationary and tighten the band locknut to 47-61 N.m (35-44
lb-ft).
16. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve
Body", Section 307-01, Install the Main Control assembly.
17. Reinstall the catalytic converter.
Parts Block
OTHER APPLICABLE ARTICLES: 02-8-2
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7L173 01
OASIS CODES: 504000, 510000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Page 5618
Band Apply Servo: Specifications
Transmission Servo Heat Shield Nut 71 - 97 in.lb
Transmission Servo Heat Shield Stud 106 - 142 in.lb
Front Band Locknut 35 - 45 ft.lb
Low/Reverse Servo Cover Screws 106 - 124 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment
Band Apply Servo: Adjustments Front Band Adjustment
Front Band Adjustment
Special Tools
Special Tool(s)
1. Raise the vehicle on a hoist.
2. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
3. CAUTION:
^ Do not allow front band adjustment screw to back out. Band strut can fall out of position;
^ Throw the locknut away. The locknut is not reusable for assembly.
Remove and discard the locknut.
4. CAUTION:
^ Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to
the locknut seal.
^ The servo must be installed prior to band adjustment.
NOTE: The wrench will click at the specified torque. Install new locknut, do not tighten at this time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment > Page 5621
Using the special tool, tighten front band adjustment screw then, back off the front band adjustment
screw exactly two (2) turns and hold that position.
5. Tighten the front band locknut.
1. Hold the front band adjustment screw stationary. 2. Tighten the front band locknut.
6. Install the shift cable.
1. Install the shift cable. 2. Install the shift cable to the manual control lever.
7. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment > Page 5622
Band Apply Servo: Adjustments Intermediate Band Adjustment
Intermediate Band Adjustment
1. Raise and support the vehicle.
2. Remove the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the
bracket.
3. Remove the digital Transmission Range (TR) sensor.
4. CAUTION:
^ Do not allow the screw to back out. Band strut can fall out of position.
^ Throw the locknut away. The locknut is not reusable for assembly.
Remove and discard the locknut.
5. CAUTION:
^ Install, but do not tighten, a new locknut on the screw. Apply petroleum jelly to the locknut seal.
^ The intermediate servo must be installed prior to band adjustment.
NOTE: The wrench will click at the specified torque. Install new locknut, do not tighten at this time.
Using the special tool, tighten the screw then, back off the screw exactly two (2) turns and hold that
position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment > Page 5623
6. Tighten the intermediate band locknut.
1. Hold the screw stationary. 2. Tighten the intermediate band locknut.
7. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
8. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital
TR sensor and tighten screws in an alternating sequence.
9. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment > Page 5624
10. Connect the digital Transmission Range (TR) sensor electrical connector.
11. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
12. Verify that the shift cable is adjusted. 13. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo
Band Apply Servo: Service and Repair Front Servo
Front Servo
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support vehicle.
3. Remove the shift cable.
1. Disconnect the shift cable from the manual control ]ever. 2. Remove the shift cable from the
bracket.
4. Remove the digital Transmission Range (TR) sensor. 5. Remove the main control valve body. 6.
Remove the Three Way Catalytic Converter (TWC).
7. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5627
Loosen the nut and position the heat shield out of the way.
8. Remove the front band locknut and unscrew the front band adjusting screw.
^ Discard the front band locknut after removal.
9. CAUTION: The servo cover is under spring pressure.
Using the special tool, remove the front band servo cover retaining ring. ^
Slowly remove tension on the J-hook nut and remove the servo cover compressor.
10. CAUTION: The special tool should be used to prevent damage to servo and bore.
Using the special tool, remove the front band servo cover, servo piston and servo piston spring. ^
Insert the special tool into the transmission case, locate on servo rod, and remove the front band
servo cover, servo piston and servo piston spring.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5628
1. Assemble the front band servo cover, front band servo piston and the servo piston spring.
1. Install the front band servo piston into the front band servo cover. 2. Install the servo piston
spring on the front band servo piston.
2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past
relief hole in case, or O-ring damage may occur.
Install the front band servo assembly into the transmission case. ^
Lubricate the front band servo cover O-ring with petroleum jelly.
3. Using the special tool, install the front band servo cover retaining ring. 4. Install the main control
valve body. 5. Adjust the front band.
6. If equipped, position the transmission servo heat shield on the transmission and install the nut. 7.
Install the three way catalytic converter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5629
8. Install the shift cable.
1. Install the shift cable. 2. Install the shift cable to the manual control lever.
9. Install the digital Transmission Range (TR) sensor.
10. Lower the vehicle.
11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
12. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5630
Band Apply Servo: Service and Repair Intermediate Servo
Intermediate Servo
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different up
shifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Remove the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the
bracket.
4. Remove the digital Transmission Range (TR) sensor. 5. Remove the Three Way Catalytic
Converter (TWC). 6. Remove the main control valve body.
7. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5631
Loosen the nut and position the heat shield out of the way.
8. Remove the intermediate band locknut and unscrew the screw.
^ Discard the intermediate band locknut after removal.
9. CAUTION: The servo cover is under spring tension. Use caution when removing.
Using the special tool, remove the intermediate band servo cover retaining ring. ^
Slowly remove tension on the J-hook nut and remove the servo cover compressor.
10. CAUTION: The special tool should be used to prevent damage to the servo, servo cover and
bore.
Using the special tool, remove the intermediate band servo cover, intermediate band servo piston
and servo piston spring. ^
Insert the special tool into the transmission case, and remove the servo cover, intermediate band
servo piston and servo piston spring.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5632
1. Assemble the intermediate band servo cover, intermediate band servo piston and the servo
piston spring.
1. Install the intermediate band servo piston into the intermediate band servo cover. 2. Install the
servo piston spring on the intermediate band servo piston.
2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past
relief hole in case, or O-ring damage may occur.
Install the intermediate band servo piston assembly into the transmission case. ^
Lubricate intermediate band servo cover O-ring with petroleum jelly.
3. Using the special tool, install the intermediate band servo cover retaining ring. 4. Adjust the
intermediate band. 5. Install the main control valve body. 6. Install the digital Transmission Range
(TR) sensor.
7. If equipped, position the transmission servo heat shield on the transmission and install the nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5633
8. Install the shift cable.
1. Install the shift cable. 2. Install the shift cable to the manual control lever.
9. Install the three way catalytic converter.
10. Lower the vehicle.
11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
12. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5634
Band Apply Servo: Service and Repair Low/Reverse Servo Assembly
Low/Reverse Servo Assembly
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle. 3. Remove the transmission pan.
4. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
5. Remove the low/reverse band servo cover.
1. Remove the low/reverse band servo cover screws. 2. Remove the low/reverse band servo cover
and gasket. Discard the low/reverse servo separator plate cover gasket.
6. Remove the low/reverse band servo piston and rod assembly.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5635
1. Clean and inspect the low/reverse band servo piston bore and the low/reverse band servo piston
and rod.
2. Install the low/reverse band servo piston and rod.
1. Install the low/reverse band servo piston and rod assembly. 2. Install a new low/reverse band
servo separator plate cover gasket. 3. Install the low/reverse band servo cover.
^ Loosely install the low/reverse band servo piston cover screws.
3. Tighten the servo cover screws in the sequence shown.
4. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
5. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5636
^ Loosely install the transmission fluid pan screws.
6. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
9. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Specifications
Extension Housing: Specifications
Extension Housing screws 27-39 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Specifications > Page 5640
Extension Housing: Service and Repair
Extension Housing Gasket
Removal
1. Raise and support the vehicle.
2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original alignment.
Mark the rear driveshaft.
3. Remove the rear driveshaft.
1. Remove the bolts. 2. Remove the rear driveshaft.
4. Remove the nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Specifications > Page 5641
5. Raise and support the transmission.
6. Remove the transmission mount.
1. Remove the screws. 2. Remove the transmission mount.
7. Remove the extension housing screws and studs.
8. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out
during removal of the extension housing.
Remove the extension housing. Discard the extension housing gasket.
Installation
1. Clean the extension housing and install new extension housing gasket. Make sure that the
parking pawl, spring and shaft are correctly installed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Specifications > Page 5642
2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup.
Install the extension housing. 1. Position the extension housing. 2. Install the extension housing
screws. 3. Install the extension housing studs.
3. Install the transmission mount.
1. Position the transmission mount on the extension housing. 2. Install the transmission
mount-to-extension housing screws.
4. Install the transmission mount into the crossmember and tighten the transmission mount nuts.
5. NOTE: Align the driveshaft with the marks made during removal to ensure correct balance.
Align and install the rear driveshaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Specifications > Page 5643
6. Install the bolts. 7. Lower the vehicle. 8. Fill the transmission to the correct fluid level and check
for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid ..............................................................................................................................
..................................................................... 10.0 qts Note: Approximately Dry Fill Capacity
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 5648
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
Type .....................................................................................................................................................
............................................................. MERCON V
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > A/T Fluid Level Check and Condition, Change
Fluid - A/T: Service and Repair A/T Fluid Level Check and Condition, Change
Fluid Pan, Gasket and Filter
Removal
1. Raise and support the vehicle.
NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail
and positioned out of the way for fluid pan removal.
If equipped, loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
- Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove
the converter.
- Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to
drain. After fluid is drained, remove the front two transmission fluid pan screws.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5651
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid
XT-5-QM meeting Ford specification MERCON
(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter.
^
Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5652
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the
vehicle.
8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
Fill transmission to the correct fluid level and check for correct transmission operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5653
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification
MERCON(R) V.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5654
Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug
Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug
Draining
CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission
fluid additives, treatments or cleaning agents. The use of these materials can affect the operation
of the transmission, resulting in internal component failure.
1. With the vehicle in PARK, position on a hoist.
2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail
and positioned aside for fluid pan removal.
If equipped, loosen the nut and position the heat shield aside.
3. Place a drain pan under the transmission fluid pan.
4. Drain the transmission fluid.
^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to
drain. After the fluid is drained, remove the front two transmission fluid pan screws.
5. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5655
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces.
Refill
1. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan
^ Loosely install the transmission fluid pan screws.
2. Tighten the transmission fluid pan screws.
^ Tighten the transmission fluid pan screws in a crisscross sequence.
3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the
vehicle.
5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
With the engine running and the transmission at normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is
needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should
be in the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5656
cross-hatched area of the fluid level indicator).
6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the
gears. 8. Check the transmission fluid level.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5657
Fluid - A/T: Service and Repair Automated Equipment
Transmission Fluid Drain and Refill-Automated Equipment
Special Tool(s)
Draining
CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission
fluid additives, treatments or cleaning agents. The use of these materials can affect the operation
of the transmission, resulting in internal component failure.
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: This is a new procedure for draining and adding transmission fluid using a suitable
transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a
suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine,
connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will
help remove any foreign material trapped in the fluid coolers.
4. Carry out the fluid exchange process.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the
vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission fluid level
and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the
correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications
Fluid Filter - A/T: Specifications
Transmission Fluid Filter Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5661
Fluid Filter - A/T: Service and Repair
Fluid Pan, Gasket and Filter
Removal
1. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to
drain. After fluid is drained, remove the front two transmission fluid pan screws.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5662
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid
XT-5-QM meeting Ford specification MERCON
(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter.
^
Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5663
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the
vehicle.
8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
Fill transmission to the correct fluid level and check for correct transmission operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5664
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification
MERCON(R) V.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications
Fluid Line/Hose: Specifications
Transmission Cooler Lines To Case Connectors 26 - 32 ft.lb
Transmission Cooler Line Nut 18 - 23 ft.lb
Transmission Fluid Cooler Tube Fitting To Radiato 10 - 16 ft.lb
Transmission Fluid Cooler Tube To Case Fitting 18 - 23 ft.lb
Transmission Cooler Lines Bracket Bolts 28 - 38 in.lb
Transmission Auxiliary Fluid Cooler Hose Clamps 27 - 35 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 5668
Fluid Line/Hose: Service and Repair
Transmission Fluid Cooler Tubes
Removal
1. Raise and support the vehicle.
2. Remove the radiator air deflector.
1. Remove the bolts. 2. Remove the radiator air deflector.
3. Remove the nut, bolt and transmission cooler line bracket.
4. Remove the transmission fluid cooler tubes.
1. Remove the clips. 2. Disconnect the fittings.
^ Use a backup wrench to hold the case fitting secure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 5669
3. Remove the nut. 4. Remove the transmission fluid cooler tubes.
Installation
1. NOTE: When a transmission fluid cooler tube is replaced, each replacement tube must be
fabricated from the same size tube as the original.
Shape a new transmission fluid cooler tube. ^
Use the prior tube as a guide.
^ Install the appropriate fittings.
2. CAUTION:
^ To prevent damage, make sure all plugs are removed from port openings before installing tubes.
^ To prevent cross threading, all tube nuts must be hand started before being torqued to
specification.
Install the transmission fluid cooler tubes. 1. Install the clips. 2. Connect the tube fittings to the
radiator. 3. Connect the tube fittings to the transmission.
^ Use a backup wrench to hold the case fitting secure.
4. Install the tube bracket nut. 5. Install the transmission fluid cooler tubes.
3. Install the nut, bolt, and transmission cooler line bracket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 5670
4. Install the radiator air deflector.
^ Install the bolts.
5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Lower the vehicle.
6. Fill transmission fluid to the proper level using the correct fluid and inspect for leaks.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility
Fluid Pan: Technical Service Bulletins A/T - 5R44E/5R55E Part Level Change/Compatibility
TSB 06-24-13
11/20/06
5R44E / 5R55E SERVICE PART LEVEL CHANGE / COMPATIBILITY
FORD: 1997 Aerostar 1997-2001 Explorer 1997-2007 Ranger 2001-2003 Explorer Sport
2001-2005 Explorer Sport Trac
MERCURY: 1998-2001 Mountaineer
ISSUE Some vehicles equipped with a 5R44E or 5R55E automatic transmission may require repair
of the transmission. This TSB is being published as informational only in order to avoid mix I match
of incorrect service parts which will cause a fluid leak. Beginning with 8/29/2006 production, the
5R44E or 5R55E automatic transmission will have a new transmission case, fluid pan, a
REUSABLE fluid pan gasket and new fluid pan screws.
ACTION Follow the Service Tips.
SERVICE TIPS
NOTE
DO NOT MIX AND MATCH PARTS OR LEAKAGE WILL OCCUR.
NOTE
THE NEW PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE
ORDERED SEPARATELY.
The 5R44E / 5R55E transmission pan gasket has been redesigned to be reusable if it is removed
for a non-leak related transmission service concern. The gasket should be inspected for damage
and cleaned, along with the mating surfaces, before reuse. The case and fluid pan rails have been
redesigned to properly mate with the new gasket to eliminate fluid leaks. The new case, pan, and
gasket maybe used to service past model transmissions from 1997.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5675
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5676
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5677
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5678
For 1997-2007 (early production) 4R44E I 5R44E and 5R55E when servicing the fluid pan gasket
(7A191), the fluid pan (7A194) or the case (7005) do not mix and match old level and new level
parts. The old level gasket, refer to Figure 3 (7A191) will be continued for past model applications.
If replacing the older design level case, refer to Figure 1 (7005) and/or old lever fluid pan, refer to
Figure 2 (7A194), ALL new components must be used. This includes the case (7005), refer to
Figure 4, fluid pan (7A194), refer to Figure 5, fluid pan gasket (7A191), refer to Figure 6 and pan
screws (W500212) (new torque specification - 7 lb-ft (10 N.m) refer to Figure 7.
For correct part numbers refer to your parts catalogue.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > Page 5679
Fluid Pan: Specifications
Transmission Fluid Pan Screws 115 - 132 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > Page 5680
Fluid Pan: Service and Repair
"For information regarding this component please refer to Transmission Filter Service And Repair"
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Specifications
Fluid Pump: Specifications
Fluid Pump Screws 16 - 21 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Transmission Mode Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair
Parking Pawl: Service and Repair
Park System
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
Loosen the nut and position the heat shield out of the way.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
5. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5691
6. Remove wire loom guide and protector.
^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
7. Disconnect the solenoid electrical connectors.
1. Disconnect shift solenoids SSB and SSD electrical connectors. 2. Disconnect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure
Control (EPC) solenoid electrical connector.
8. CAUTION: The TCC solenoid and converter modulator valve may pop out of their bore. This
may damage the solenoid or converter modulator
valve.
Remove the EPC, SSB, and SSD solenoids. 1. Remove the wire harness. 2. Remove the solenoid
clamp screws. 3. Remove the solenoid clamp. 4. Remove the EPC, SSB, and SSD solenoids.
9. CAUTION: Do not pry on the other wires or damage to the connector case surface may result.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5692
Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector from the transmission case
(16 pin) electrical connector. 1. Disconnect the TSS sensor electrical connector. 2. Remove the
TSS sensor wire locator.
10. CAUTION: Do not overstretch the retaining spring.
Remove the transmission case (16 pin) electrical connector retaining spring.
11. CAUTION: Do not damage the connector or harness.
Remove the transmission case (16 pin) electrical connector. ^
Compress the tabs on the connector.
^ Push the connector out of the transmission case.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5693
12. Remove the manual control valve detent lever spring.
1. Remove the screw. 2. Remove the spring.
13. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner
lever pin.
Remove the manual valve inner lever nut.
14. Remove the manual valve inner lever and parking lever actuating rod.
15. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they can be installed in their original alignment.
Mark the rear driveshaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5694
16. Remove the rear driveshaft.
1. Remove the bolts. 2. Remove the rear driveshaft.
17. If equipped, remove the transfer case.
18. NOTE:
^ If damage is found to the parking gear, the transmission must be removed and disassembled.
^ The parking pawl, parking pawl return spring and parking pawl shaft may fall out during removal
of the extension housing.
Remove the extension housing and discard the extension housing gasket.
19. Inspect the parking pawl, parking pawl return spring and the parking pawl shaft.
^ Install new components if required.
Installation
1. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup. Verify that the output shaft is
locked in the, PARK position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5695
Align the flats of the manual valve inner lever with the flats on the manual control lever shaft. Install
the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft.
2. CAUTION: Do not bend the manual valve inner lever pin.
Install the manual valve inner lever nut.
3. Install the manual valve detent spring.
4. Clean the extension housing and install a new extension housing gasket. Make sure that the
parking pawl, spring, and shaft is correctly installed.
5. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5696
Install the extension housing. 1. Position the extension housing. 2. Install the extension housing
screws. 3. Install the extension housing stud.
6. If equipped, install the transfer case.
7. NOTE: Align the drive shaft with the marks made during removal to ensure correct balance.
Install the rear driveshaft bolts.
8. NOTE:
^ Make sure the tab is in the lock position.
^ Install new O-rings on the transmission case (16 pin) electrical connector.
Install the transmission case (16 pin) electrical connector. ^
Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly.
9. Press the transmission case (16 pin) electrical connector through the case until a click is heard.
10. CAUTION: Align the slot on the TSS Sensor electrical connector with the slot in the 16 pin case
connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5697
Install the TSS sensor wire. 1. Install the TSS sensor wire into (16 pin) electrical connector. 2.
Install the TSS sensor wire into locator.
11. CAUTION: Do not overstretch the retaining spring.
Install the transmission case (16 pin) electrical connector retaining spring.
12. Install the EPC, SSD, and SSB solenoids.
13. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5698
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
14. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors.
15. CAUTION: Excessive pressure may break the retaining pins.
Install the wire loom guide and protector. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the wire loom guide
and protector.
16. Install the transmission fluid pan.
1. Install a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the
transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5699
17. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
18. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 19. Lower
the vehicle.
20. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur While the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
21. Fill transmission to correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T
- 5R55E 1st/2nd Gear Whining Noise
Planetary Gears: Customer Interest A/T - 5R55E 1st/2nd Gear Whining Noise
Article No. 02-22-2
11/11/02
^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH
5R55E TRANSMISSION AND 4.0L ENGINE ONLY
^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES
EQUIPPED WITH 4.0L ENGINE ONLY
FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER
ISSUE
Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002,
equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of
noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary
assemblies and/or the driveshaft.
ACTION
Verify that only these conditions exist and no DTCs are present. If other conditions are present and
DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and
only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using
the chart provided, select the parts that need to be replaced.
NOTE
IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED.
SERVICE PROCEDURE
Gear Whine Service Procedure
1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need
to be replaced, refer to Application and Component replacement chart shown.
2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate
Workshop Manual section for driveshaft removal/replacement.
3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual,
Section 307-01, Transmission Removal procedures, remove the transmission.
4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement
chart.
NOTE
REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED.
DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS
ARE NOT REQUIRED FOR THIS PROCEDURE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T
- 5R55E 1st/2nd Gear Whining Noise > Page 5708
NOTE
BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE.
5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly
(7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond
the Reverse Planetary assembly.
6. Using the appropriate Transmission Assembly procedures, assemble the transmission and
install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service
Forward Planetary Assembly (XL2Z-7A398-AA).
7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission
Installation procedures, install transmission.
8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the
appropriate application listed.
9. Verify repair. Clear DTCs.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
022202A Replace Transmission 5.5 Hrs.
Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission
5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2
022202B Replace Transmission 7.0 Hrs.
Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission
5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4
022202C Replace Driveshaft 0.4 Hr.
Only 2002-2003 Explorer Sport Trac 4x2
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A398 42
OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T
- 5R55E 1st/2nd Gear Whining Noise > Page 5709
DISCLAIMER
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov
> 02 > A/T - 5R55E 1st/2nd Gear Whining Noise
Planetary Gears: All Technical Service Bulletins A/T - 5R55E 1st/2nd Gear Whining Noise
Article No. 02-22-2
11/11/02
^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH
5R55E TRANSMISSION AND 4.0L ENGINE ONLY
^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES
EQUIPPED WITH 4.0L ENGINE ONLY
FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER
ISSUE
Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002,
equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of
noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary
assemblies and/or the driveshaft.
ACTION
Verify that only these conditions exist and no DTCs are present. If other conditions are present and
DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and
only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using
the chart provided, select the parts that need to be replaced.
NOTE
IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED.
SERVICE PROCEDURE
Gear Whine Service Procedure
1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need
to be replaced, refer to Application and Component replacement chart shown.
2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate
Workshop Manual section for driveshaft removal/replacement.
3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual,
Section 307-01, Transmission Removal procedures, remove the transmission.
4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement
chart.
NOTE
REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED.
DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS
ARE NOT REQUIRED FOR THIS PROCEDURE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov
> 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5715
NOTE
BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE.
5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly
(7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond
the Reverse Planetary assembly.
6. Using the appropriate Transmission Assembly procedures, assemble the transmission and
install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service
Forward Planetary Assembly (XL2Z-7A398-AA).
7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission
Installation procedures, install transmission.
8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the
appropriate application listed.
9. Verify repair. Clear DTCs.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
022202A Replace Transmission 5.5 Hrs.
Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission
5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2
022202B Replace Transmission 7.0 Hrs.
Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission
5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4
022202C Replace Driveshaft 0.4 Hr.
Only 2002-2003 Explorer Sport Trac 4x2
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A398 42
OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov
> 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5716
DISCLAIMER
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Page 5720
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Page 5721
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Page 5722
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5725
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5726
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5727
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5728
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5729
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5730
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5731
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5732
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5733
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5734
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5735
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5736
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5737
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5738
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5739
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5740
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5741
Pressure Regulating Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5742
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5743
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5744
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5745
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module (PCM) varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift
strategy.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5746
Pressure Regulating Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5747
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5748
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5749
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T
Seals and Gaskets: Service and Repair Extension Housing Seal, A/T
Extension Housing Oil Seal
Special Tools
Special Tool(s)
Removal
1. Raise and support the vehicle.
2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original alignment.
Mark the rear driveshaft.
3. Remove the rear driveshaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 5754
1. Remove the rear driveshaft bolts. 2. Remove the rear driveshaft.
4. Using the special tools, remove the extension housing seal.
5. CAUTION: Use the extension housing bushing remover carefully so that the seal area is not
damaged.
Using the special tool, remove the extension housing bushing.
Installation
1. CAUTION: The lube hole in the extension housing bushing must be aligned with the lube groove
in the extension housing. This groove is located
at the 3 o'clock position when viewed from the rear.
NOTE: Inspect the counterbore of the extension housing for burrs. Remove any burrs from the
extension housing counterbore with an oil stone.
Position the extension housing bushing into the extension housing.
2. CAUTION: The tool will bottom when bushing is in the correct position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 5755
Using the special tool, install the extension housing bushing.
3. Position new extension housing seal with drain hole in the 6 o'clock position.
4. Using the special tool, install the extension housing seal.
5. NOTE: Inspect the driveshaft slip-yoke for wear and damage. Install a new component if
required.
Align the driveshaft with the marks made during removal to ensure correct balance.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 5756
6. Install the rear driveshaft bolts. 7. Lower the vehicle. 8. Fill the transmission to the correct fluid
level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-OM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 5757
Seals and Gaskets: Service and Repair Shift Shaft Seal
Manual Control Lever Shaft and Seal
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition. ,
Disconnect the battery ground cable.
2. Raise and support vehicle.
3. NOTE: If equipped, transmission servo heat shield needs to be unclipped from the fluid pan rail
and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. NOTE: It is not necessary to remove the transmission fluid filter to carry out this procedure.
Remove the transmission fluid pan.
5. Remove the digital Transmission Range (TR) sensor.
6. Remove the manual control valve detent lever spring.
1. Remove the manual control valve detent lever spring screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 5758
2. Remove the manual control valve detent lever spring.
7. CAUTION: Do not damage the valve inner lever pin.
Remove the manual valve inner lever nut.
8. Separate the manual valve inner lever and the parking lever actuating rod.
9. CAUTION: Do not damage the case fluid pan rail.
Remove the manual control lever shaft spring pin. ^
Tap lightly on each side of the manual control lever shaft spring pin with a drift punch.
^ Pry the spring pin out of its bore.
10. Remove the manual control lever shaft.
11. CAUTION: Do not damage the bore.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 5759
Remove the manual control lever shaft seal.
Installation
1. Using the special tool, install the manual control lever shaft seal.
^ Lubricate the manual control lever shaft seal with petroleum jelly.
2. Install the manual control lever shaft.
3. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin
bore in the transmission case. ^
Tap the manual control lever shaft spring pin into the transmission case.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 5760
4. Align flats of the manual valve inner lever with flats on the manual control lever shaft. Install the
manual valve inner lever and parking lever
actuating rod onto the manual control lever shaft.
5. CAUTION: Do not bend the manual valve inner lever pin.
Install the manual valve inner lever nut.
6. CAUTION: Park pawl actuating rod must be correctly installed into parking pawl and guide cup
located in extension housing. Verify park
linkage function.
Verify that the output shaft is locked in the PARK position.
7. Install the manual valve detent spring. 8. Install the transmission fluid pan with new pan gasket.
9. If equipped, position the servo heat shield over the servos and clip it to the pan rail.
10. Install the digital Transmission Range (TR) sensor. 11. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 5761
12. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
13. Fill the transmission to correct level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification
MERCON(R) V.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5766
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5767
Transmission Mode Switch: Service and Repair
Transmission Control Switch
Removal and Installation
1. Remove the Transmission Control Switch (TCS).
1. Remove the cover. 2. Remove the TCS.
2. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 5771
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 5772
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 5773
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 5774
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 5775
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5781
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5782
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5785
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5786
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5787
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5788
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5789
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5790
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5791
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5792
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5793
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5794
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5795
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5796
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5797
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5798
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5799
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5800
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5801
Transmission Speed Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5802
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5803
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5804
Transmission Speed Sensor: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5805
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5806
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5807
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5808
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5814
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5815
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5816
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5817
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5818
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5819
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5820
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5821
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5822
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5823
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5824
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5825
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5826
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5827
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5828
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5829
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5830
Transmission Temperature Sensor/Switch: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5831
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5832
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5833
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5834
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Specifications
Shift Interlock Solenoid: Specifications
Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Specifications > Page 5839
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Removal and Installation
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag Supplemental Restraint System (SRS) components and
before servicing, replacing, adjusting or striking components near the front or side air bag sensors,
such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please
refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at
or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery
ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped).
Disconnect the battery ground cable. Wait at least one minute before proceeding with the
procedure to allow the backup power supply to deplete its energy.
2. Remove the lower steering column opening finish panel.
1. Remove the screws and position the hood release handle out of the way. 2. Remove the two
screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining
clips and remove the lower steering column opening finish panel.
3. Remove the five bolts and the lower steering column opening finish panel reinforcement.
4. Remove the four nuts and lower the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Specifications > Page 5840
5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering
column.
6. Disconnect the electrical connector and remove the insert plate and shift lock actuator.
7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary
to install a new clip for installation.
Remove and discard the clip.
8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications
Shift Solenoid: Specifications
Solenoid Clamp Screws 53 - 71 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications > Page 5844
Shift Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications > Page 5845
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications > Page 5846
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications > Page 5847
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5850
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5851
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5852
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5853
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5854
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5855
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5856
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5857
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5858
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5859
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5860
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5861
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5862
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5863
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5864
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5865
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5866
Shift Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5867
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5868
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5869
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5870
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5871
Shift Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5872
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5873
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5874
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Adjustments
Shifter A/T: Adjustments
Selector Lever Indicator Adjustment
1. Remove the lower steering column opening finish panel.
1. Remove the screws and position the hood release handle out of the way. 2. Remove the two
screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining
clips and remove the lower steering column opening finish panel.
2. Remove the five bolts and the lower steering column opening finish panel reinforcement. 3.
Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise
two detents (OD position). 4. Hang a 1.4 kg (3 lbs.) weight on the gearshift lever.
5. Rotate the thumb wheel to center the selector lever indicator in the middle of the OD position. 6.
Remove the 1.4 kg (3 lbs.) weight. 7. Rotate the gearshift lever into each detent to verify that the
selector lever indicator matches the selected range. Readjust, if necessary.
8. Install the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Adjustments > Page 5878
9. Install the lower steering column opening finish panel and the hood release handle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Adjustments > Page 5879
Shifter A/T: Service and Repair
Selector Lever
Removal and Installation
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag Supplemental Restraint System (SRS) components and
before servicing, replacing, adjusting or striking components near the front or side air bag sensors,
such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please
refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at
or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery
ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped).
Disconnect the battery ground cable. Wait at least one minute before proceeding with the
procedure to allow the backup power supply to deplete its energy.
2. Remove the lower steering column opening finish panel.
1. Remove the screws and position the hood release handle out of the way. 2. Remove the two
screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining
clips and remove the lower steering column opening finish panel.
3. Remove the five bolts and the lower steering column opening finish panel reinforcement.
4. Remove the four nuts and lower the steering column.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Adjustments > Page 5880
5. Remove the ignition switch lock cylinder.
1. Rotate the ignition switch lock cylinder to the RUN position. 2. Press the lock cylinder release pin
and remove the ignition switch lock cylinder.
6. Remove the lower steering column shroud.
1. If so equipped, remove the tilt wheel handle and shank. 2. Remove the three screws. 3. Remove
the lower steering column shroud.
7. Remove the upper steering column shroud.
8. Disconnect the Transmission Control Switch (TCS) harness connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Adjustments > Page 5881
9. Separate the TCS harness from the locators and the gearshift lever cover from the steering
column.
10. CAUTION: Never reinstall the old gearshift lever pin.
Remove the gearshift lever pin and the gearshift lever. Discard the gearshift lever pin.
11. To install, reverse the removal procedure. 12. Prove out the air bag system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications
Shift Cable: Specifications
Bolts Retaining The Shift Cable Bracket To The Transmission 30 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 5886
Shift Cable: Adjustments
Selector Lever Cable Adjustment
1. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it
counterclockwise two detents (OD position). 2. Hang a 1.4 kg (3 lbs.) weight on the gearshift lever.
3. Raise and support the vehicle.
4. CAUTION: Adjust the shift cable only in the OD position.
Adjust the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Insert a flat
blade screwdriver between the end of the shift cable adjustment lock tab and the housing and twist
the screwdriver to disengage the
lock tab snaps. Pull the shift cable adjustment lock tab outward to the unlock position.
3. Place the manual control lever in the OD position.
^ Rotate the manual control lever forward until travel stops. Then, move the manual control lever
back two detents to the OD position.
4. Connect the shift cable to the manual control lever. 5. Push the shift cable adjustment lock tab
inward to the lock position.
5. Lower the vehicle. 6. Remove the 1.4 kg (3 lbs.) weight. 7. Verify that the engine will start in P
and N and that the reversing lamps illuminate in R. If not, repeat the adjustment procedure. 8.
Check that the Digital Transmission Range (DTR) sensor adjustment is correct.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 5887
Shift Cable: Service and Repair
Selector Lever Cable and Bracket
Removal
1. Raise and support the vehicle.
2. Disconnect the shift cable from the transmission.
1. Disconnect the shift cable from the manual control lever. 2. Depress the lock tabs and
disconnect the shift cable from the shift cable bracket.
3. Remove the bolts and the shift cable bracket from the transmission. 4. Lower the vehicle.
5. Disconnect the shift cable from the steering column.
1. Disconnect the shift cable from the transmission selector lever arm and support. 2. Disconnect
the shift cable from the steering column bracket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 5888
6. Push the rubber grommet through the bulkhead.
7. Locate the shift cable retainer tabs, protruding through the floor pan, underneath the carpet and
insulation. While squeezing the tabs together, push
the tabs out of the floor pan.
8. From the engine compartment, remove the shift cable from the vehicle.
Installation
1. From inside the vehicle, feed the shift cable through the opening in the bulkhead and downward
toward the transmission. Do not seat the rubber
grommet in the bulkhead opening at this time.
2. Connect the shift cable to the steering column.
1. Connect the shift cable to the steering column bracket. 2. Connect the shift cable to the
transmission selector lever arm and support.
3. From the engine compartment, connect the shift cable retainer to the floor pan.
4. From inside the vehicle, verify that the retainer tabs have seated on the floor pan. Reposition the
insulation and the carpet.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 5889
5. Seat the rubber grommet in the bulkhead opening. 6. Rotate the gearshift lever clockwise until it
bottoms out (first gear), then rotate it counterclockwise two detents (OD position). 7. Hang a 1.4 kg
(3 lbs.) weight on the gearshift lever. 8. Raise and support the vehicle.
9. Position the shift cable bracket and install the bolts.
10. Connect the shift cable to the shift cable bracket. Do not connect the shift cable to the manual
control lever at this time. 11. Adjust the shift cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations
Torque Converter Clutch Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Page 5893
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Page 5894
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Page 5895
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5898
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5899
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5900
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5901
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5902
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5903
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5904
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5905
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5906
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5907
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5908
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5909
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5910
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5911
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5912
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5913
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5914
Torque Converter Clutch Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5915
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5916
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5917
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5918
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5919
Torque Converter Clutch Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5920
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5921
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5922
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips
Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Service Tips
Article No. 03-14-8
07/21/03
TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS
FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT,
MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003
THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003
WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003
EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR
MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE
1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER
This article supersedes TSB 00-1-5.
ISSUE The number one cause for repeat transmission repairs is that contamination from the
transmission cooler system (lines and tank) will work their way back into the rebuilt or new
transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank
Heated Cooler Line Flusher" Rotunda Tool number 22-00001.
ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the
transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The
use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to
remove contamination from its cooling system. Refer to the following Service Procedure and
Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher").
SERVICE PROCEDURE
Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant
removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher"
uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system
contamination.
Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are
2 issues with this method:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 5927
^ Residual solvent contamination can cause damage to friction bonding materials within the
transmission (Clutches and Bands).
^ Lack of fluid heating and agitation prevents this method from completely removing contamination
from lines, in-radiator coolers and auxiliary coolers.
Aerosol Solvents should never be used for several reasons.
^ They do not provide the volume necessary to remove heavy contaminants.
^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they
are as the solvent dries.
NOTE
YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING
PROCEDURE.
A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the
transmission) is to locate the return cooler line fitting on the transmission case. Refer to the
following lists:
Rear Wheel Drive
^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line.
^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line.
^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S
- The TOP transmission case filling receives the return line.
Front Wheel Drive
^ CD4E - The REAR or Pump End transaxle case fitting receives the return line.
^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line.
^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the
return line.
NOTE
IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED
BEFORE FLUSHING THE COOLER OR COOLER LINES.
Purge the cooler and cooler line before flushing:
Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This
valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the
back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or
Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher").
Flush Procedure
1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with
transmission fluid.
2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using.
3. Install line adapters into the transmission cooler lines.
4. Attach the flusher's blue line to the transmission return cooler line quick disconnect.
5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect.
a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing
procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line
Flusher").
6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a
forward/normal flow direction for an additional 10-15 minutes.
For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001),
contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 5928
CAUTION
THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH
THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN
1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Page 5929
Transmission Cooler: Specifications
Transmission Auxiliary Fluid Cooler Bolts 45 - 62 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Page 5930
Transmission Cooler: Description and Operation
Transmission Cooling
Transmission Cooling Components (Mountaineer Shown, Explorer Similar)
All vehicles with automatic transmissions are equipped with integral transmission fluid coolers. The
integral transmission fluid cooler is contained inside of the radiator outlet tank and cannot be
repaired separately. All (AWD) vehicles are equipped with the transmission auxiliary fluid cooler
which is mounted in front of the radiator. In operation, transmission fluid travels from the
transmission to the integral transmission fluid cooler to the transmission auxiliary fluid cooler then
back to the transmission. The integral transmission fluid cooler transfers heat from the transmission
fluid to the engine coolant. The transmission auxiliary fluid cooler transfers heat from the
transmission fluid to the outside air.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Transmission Cooler: Initial Inspection and Diagnostic Overview
WARNING: Never remove the radiator cap under any conditions while the engine is operating.
Failure to follow these instructions could result in personal injury and/or damage to the cooling
system or engine. To avoid having scalding hot coolant or steam blow out of the radiator, use
extreme care when removing the radiator cap from a hot radiator. Wait until the engine has cooled,
then wrap a thick cloth around the radiator cap and turn it slowly to the first stop. Step back while
the pressure is released from the cooling system. When you are certain all the pressure has been
released, press down on the radiator cap (with a cloth), turn and remove.
Check for fluid leakage. If fluid leakage is found at any of the transmission fluid cooling
components, the component must be replaced.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5933
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Page 5934
Transmission Cooler: Service and Repair
Auxiliary Transmission Fluid Cooler
Removal
1. Disconnect the battery cables. 2. Raise and support the vehicle.
3. Remove the radiator air deflector.
1. Remove the bolts. 2. Remove the radiator air deflector.
4. Place a drain pan under the transmission auxiliary fluid cooler.
5. Loosen the two upper radiator hold down screws.
6. Remove the transmission auxiliary fluid cooler.
1. Disconnect the hoses. 2. Remove the bolts. 3. Remove the transmission auxiliary fluid cooler.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Page 5935
1. Follow the removal procedure in reverse order.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Page 5942
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Page 5943
Transmission Mode Switch: Service and Repair
Transmission Control Switch
Removal and Installation
1. Remove the Transmission Control Switch (TCS).
1. Remove the cover. 2. Remove the TCS.
2. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Specifications
Transmission Mount: Specifications
Transmission Mount Nuts To Crossmember 64 - 81 ft.lb
Transmission Mount-To-Extension Housing screws 64 - 81 ft.lb
Crossmember Screws 63 - 87 ft.lb
Crossmember Nuts 65 - 85 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Specifications > Page 5947
Transmission Mount: Service and Repair
Transmission Insulator and Retainer
Removal
NOTE: 4x2 procedure shown. 4x4 similar, front drive shaft will need to be removed.
1. Raise and support the vehicle.
2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original alignment.
Mark the rear driveshaft.
3. Remove the rear driveshaft.
1. Remove the bolts. 2. Remove the rear driveshaft.
4. Remove the transmission mount nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Specifications > Page 5948
5. Raise and support the transmission.
6. Remove the transmission mount.
1. Remove the screws. 2. Remove the transmission mount.
Installation
1. Install the transmission mount.
1. Position the transmission mount on the extension housing. 2. Install the transmission
mount-to-extension housing screws.
2. Install the transmission mount into the crossmember and tighten the nuts.
3. NOTE: Align the driveshaft with the marks made during removal to ensure correct balance.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Specifications > Page 5949
Align and install the rear driveshaft.
4. Install the bolts. 5. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5953
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5954
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5955
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5956
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5957
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5963
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5964
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5967
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5968
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5969
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5970
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5971
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5972
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5973
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5974
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5975
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5976
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5977
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5978
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5979
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5980
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5981
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5982
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5983
Transmission Speed Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5984
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5985
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5986
Transmission Speed Sensor: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5987
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 5988
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 5989
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 5990
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5996
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5997
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5998
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5999
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6000
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6001
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6002
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6003
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6004
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6005
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6006
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6007
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6008
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6009
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6010
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6011
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6012
Transmission Temperature Sensor/Switch: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6013
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6014
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6015
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Page 6016
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No
2nd, 3rd Gear/No Engine Braking/DTC's Set
Valve Body: Customer Interest A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set
Article No. 03-22-10
11/10/03
TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT
WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733,
P1762 - VEHICLES BUILT BEFORE 12/1/2001
FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002
EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC
MERCURY: 1997-2001 MOUNTAINEER
This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage.
ISSUE
Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions:
^ No 2nd Gear
^ No 3rd Gear
^ No Engine Braking In Manual 1st.
Out of specification pressures controlled by the transmission main control valve body separator
plate may be the cause.
ACTION
Verify the condition, the main control valve body separator plate may need to be updated to the
latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No
2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6025
CAUTION
A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT
7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS
APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING.
NOTE
THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT
MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC
CONDITIONS.
NOTE
AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS
TSB.
1. Verify that one or more of the following conditions exist.
^ Low Line Pressure While In Drive At WOT
^ No 2nd And/Or No 3rd Gear
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No
2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6026
^ No Engine Braking In Manual 1st
^ DTC P0732, P0733 Or P1762
2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the
installation procedures found in the kit.
3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop
Manual, in-vehicle service, main control valve body.
4. After completing the procedure, verify the condition has been corrected.
5. Clear all DTCs.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 03-11-9, 02-13-8 02-08-2
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032210A Replace Separator Plate 2.8 Hrs.
And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve
Body And Diagnosis)
DEALER CODING
CONDITION
BASIC PART NO. CODE
D100 D8
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov >
03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set
Valve Body: All Technical Service Bulletins A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set
Article No. 03-22-10
11/10/03
TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT
WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733,
P1762 - VEHICLES BUILT BEFORE 12/1/2001
FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002
EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC
MERCURY: 1997-2001 MOUNTAINEER
This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage.
ISSUE
Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions:
^ No 2nd Gear
^ No 3rd Gear
^ No Engine Braking In Manual 1st.
Out of specification pressures controlled by the transmission main control valve body separator
plate may be the cause.
ACTION
Verify the condition, the main control valve body separator plate may need to be updated to the
latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov >
03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6032
CAUTION
A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT
7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS
APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING.
NOTE
THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT
MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC
CONDITIONS.
NOTE
AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS
TSB.
1. Verify that one or more of the following conditions exist.
^ Low Line Pressure While In Drive At WOT
^ No 2nd And/Or No 3rd Gear
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov >
03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6033
^ No Engine Braking In Manual 1st
^ DTC P0732, P0733 Or P1762
2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the
installation procedures found in the kit.
3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop
Manual, in-vehicle service, main control valve body.
4. After completing the procedure, verify the condition has been corrected.
5. Clear all DTCs.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 03-11-9, 02-13-8 02-08-2
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032210A Replace Separator Plate 2.8 Hrs.
And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve
Body And Diagnosis)
DEALER CODING
CONDITION
BASIC PART NO. CODE
D100 D8
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 6034
Valve Body: Specifications
Main Control Valve Body Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 6035
Valve Body: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 6036
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 6037
Valve Body: Description and Operation
For complete Description and Operation of the Valve Body, refer to Transmission and Drivetrain /
Automatic Transmission/Transaxle / Description and Operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly
Valve Body: Service and Repair Disassembly and Assembly
Main Control Valve Body
Special Tools
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6040
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6041
Disassembly
1. CAUTION: The SSC solenoid may pop out of its bore. This may damage the solenoid.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6042
Remove the SSA and the SSC clamp and SSA and SSC solenoid. 1. Remove the solenoid clamp
screw. 2. Remove the solenoid clamp. 3. Remove the SSA and SSC solenoids.
2. CAUTION:
^ The Torque Converter Clutch solenoid (TCC) solenoid may pop out of its bore. This may damage
the solenoid.
^ The converter modulator valve may come out after the TCC solenoid. This may cause damage to
the valve.
Remove the SSB, SSD, torque converter clutch solenoid, and the EPC solenoid. 1. Remove the
solenoid clamp screw. 2. Remove the solenoid clamp. 3. Remove the SSB, SSD, torque converter
clutch solenoid and the EPC solenoids.
3. Rotate the main control valve body so that the main control to case gasket is facing up.
4. CAUTION:
^ Valves may come out when rotating the main control valve body.
^ The extension housing lube orifice and relief valves may stick to the separator plate.
NOTE: Discard the main control to case gasket.
Remove the valve body separator plate screws. 1. Remove the main control to case gasket and
discard. 2. Remove the valve body separator plate screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6043
5. Remove valve body separator plate and main control to separating plate gasket.
1. Remove valve body separator plate. 2. Remove main control to separator plate gasket and
discard.
6. Remove the extension housing lube orifice and the metal silver Electronic Pressure Control
(EPC) limit relief valve and spring.
1. Remove the extension housing lube orifice. 2. Remove the silver metal EPC limit relief valve and
spring.
7. Remove the black plastic converter relief valve and spring.
8. Remove the Electronic Pressure Control (EPC) limit circuit screen.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6044
9. Remove the four main control valve body check balls.
Assembly
1. CAUTION: Do not lose parts when cleaning or servicing.
Thoroughly clean all parts in solvent and blow dry with moisture free compressed air.
2. CAUTION: Do not stone, file or sand the valves. This will remove the anodized finish and may
result in further main control or transmission
damage.
After cleaning the main control valve body, carry out the following: ^
Inspect all valve and plug bores for scoring or burrs.
^ Check all fluid passages for obstructions.
^ Inspect all valves and plugs for burrs.
^ Inspect all mating surfaces for burrs or distortion.
^ Inspect all springs for distortion.
^ Check all valves and plugs for free movement in their respective bores. ^
Valves and plugs, when dry, must fall from their own weight into their respective bores.
^ Roll the manual valve on a flat surface to check for a bent condition.
3. Clean and inspect the EPC solenoid screens.
4. Remove and install new shift solenoid O-rings.
5. Clean and inspect the torque converter clutch solenoid.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6045
6. CAUTION: Make sure that the screen is correctly located.
Clean and inspect the Electronic Pressure Control (EPC) limit circuit screen. Install the EPC limit
circuit screen.
7. Install the four main control valve body check balls.
8. CAUTION: The springs and valves are not interchangeable. Damage to transmission may occur.
Install the dark color plastic converter relief valve and spring.
9. NOTE: The springs and valves are not interchangeable.
Install the extension housing lube orifice and the metal silver Electronic Pressure Control (EPC)
limit relief valve and spring. 1. Install the extension housing lube orifice. 2. Install the silver metal
EPC limit relief valve and spring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6046
10. NOTE:
^ Apply petroleum jelly on the valve body separator plate to hold the main control to separator plate
gasket in place.
^ Use new separator plate main control to separator plate gasket on installation.
Install the main control valve body separator plate and gasket to the main control. 1. Position the
main control valve body separator plate to the main control gasket and install separator plate to
main control valve body. 2. Install, do not tighten, the three screws.
11. Install the special tools into the main control valve body.
12. Tighten the screws.
13. NOTE:
^ Apply petroleum jelly on the separator plate surface to hold the gasket in place.
^ Use new separator plate gasket on installation.
Install new main control to case gasket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6047
14. Remove the special tools from the main control valve body. 15. Rotate the main control valve
body so the valve body separator plate is facing down.
16. CAUTION: All solenoid electrical connectors must face upward on installation.
NOTE: ^
All shift solenoids are interchangeable.
^ If the TCC valve came out during disassembly, use caution when installing the torque converter
clutch solenoid.
Install the SSB, SSD, TCC and EPC solenoids. 1. Install the TCC solenoid. 2. Install the SSB and
SSD solenoids. 3. Install the EPC solenoid.
17. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp and the screw. 1. Position the solenoid clamp on the main control valve
body. 2. Install the screw.
18. CAUTION: The shift solenoid electrical terminals must face up on installation.
NOTE: The shift solenoids are interchangeable. Install the SSA and the SSC shift solenoids.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6048
19. Install the solenoid clamp and the screw.
1. Position the solenoid clamp on the main control valve body. 2. Install the screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6049
Valve Body: Service and Repair Removal and Installation
Main Control Valve Body
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle. 3. Place a drain pan under the transmission fluid pan.
4. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6050
5. Drain transmission fluid.
^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to
drain. After fluid is drained remove the front two transmission fluid pan screws.
6. NOTE: If a transmission has been disassembled to install new parts and the valves in the main
control valve body stick repeatedly from foreign
material, the torque converter must be removed and cleaned by using a suitable torque
converter/fluid cooler cleaner.
Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard
the transmission fluid pan gasket.
7. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
8. Unclip main control valve body wire harness.
1. Lift up on wire harness guide and protector and disengage the retaining pins from the solenoid
clamps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6051
9. Disconnect the six solenoid electrical connectors.
1. Disconnect the SSA, SSB, SSC and SSD electrical connectors. 2. Disconnect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure
Control (EPC) solenoid electrical connector.
10. Remove the manual control valve detent lever spring.
1. Remove the manual control valve detent lever spring screw. 2. Remove the manual control valve
detent lever spring.
11. Remove the low/reverse servo.
1. Remove the low/reverse servo cover screws. 2. Remove the low/reverse band servo cover and
gasket. Discard the low/reverse servo separator plate cover gasket.
12. Remove the low/reverse band servo piston and rod.
13. CAUTION: Support the main control valve body.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6052
Do not remove the two (gold) screws specified.
14. CAUTION: Support the main control valve body.
Remove the screws.
15. Remove the main control valve body.
Installation
1. Install the special tool into the transmission case.
2. NOTE: Make sure main control to case gasket is correctly aligned.
Install new main control to case gasket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6053
3. Position the main control valve body with the two special tools as a guide.
4. NOTE: The main control valve body screws will be tightened in later steps.
Loosely install four M6 x 45 mm (1.8 inch) screws.
5. NOTE: The main control valve body screws will be tightened in later steps.
Loosely install two M6 x 35 mm (1.4 inch) screws.
6. Remove the special tools.
7. NOTE: The main control valve body screws will be tightened in later steps.
Loosely install the M6 x 30 mm (1.2 inch) screw.
8. NOTE: The main control valve body screws will be tightened in later steps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6054
Loosely install the sixteen M6 x 40 mm (1.6 inch) main,control valve body screws.
9. Tighten the main control valve body screws in the sequence shown.
10. Install the manual control valve detent lever spring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6055
11. Install the low/reverse band servo piston and rod.
12. Install the low/reverse band servo cover.
1. Install the low/reverse band servo cover and gasket. 2. Loosely install the low/reverse servo
piston cover screws.
13. Tighten the servo cover screws in the sequence shown.
14. Connect the six solenoid electrical connectors.
1. Connect SSA, SSB, SSC, and SSD electrical connectors. 2. Connect the Torque Converter
Clutch (TCC) solenoid electrical connector. 3. Connect the Electronic Pressure Control (EPC)
solenoid electrical connector.
15. CAUTION: Excessive pressure may break the locating pins.
Install the main control valve body wire harness. ^
Align the retaining pins to the holes in the solenoid clamps and press in the main control valve body
wire harness guide and protector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6056
16. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
17. Install the transmission fluid pan.
1. Position anew transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the
transmission fluid pan.
18. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
19. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 20. Lower
the vehicle.
21. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6057
condition and will eventually return to normal operating condition.
Connect the battery ground cable.
22. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair
Wiring Harness: Service and Repair
Internal Harness Service
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect vehicle harness from transmission case (16 pin) connector. 4. Drain the transmission
fluid.
5. NOTE: The main control assembly does not need to be removed.
Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the
transmission fluid filter.
6. Remove main control valve body wire loom.
^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6061
7. Disconnect the solenoid electrical connectors.
1. Disconnect the SSA, SSB, SSC, and the SSD electrical connectors. 2. Disconnect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure
Control (EPC) solenoid electrical connector.
8. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of their bore. This may damage
the solenoid or converter modulator valve.
^ CAUTION: Shift solenoids may pop out of their bore. This may damage the solenoids.
Remove the EPC and SSB solenoids. 1. Remove the solenoid clamp screws. 2. Remove the
solenoid clamp. 3. Remove the EPC and SSB solenoids.
9. CAUTION: Do not pry on the other wires or damage the connector case surface.
Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector from the transmission case
(16 pin) electrical connector. 1. Disconnect the TSS sensor electrical connector. 2. Remove from
the TSS sensor wire locator.
10. CAUTION: Do not overstretch the retaining spring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6062
Remove the transmission case (16 pin) electrical connector retaining spring.
11. CAUTION: Do not damage the connector or harness.
Remove the transmission case (16 pin) electrical connector. ^
Compress the tabs on the transmission case (16 pin) electrical connector.
^ Push the transmission case (16 pin) electrical connector out of transmission case.
Installation
1. NOTE:
^ Make sure the tab is in the lock position.
^ Install new O-rings on the transmission case (16 pin) electrical connector.
Install the transmission case (16 pin) electrical connector. ^
Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6063
2. Press the transmission case (16 pin) electrical connector through the case until a click is heard.
3. CAUTION: Align the slot on the TSS Sensor electrical connector with the slot in the 16 pin case
connector.
Install the TSS sensor wire. 1. Install TSS sensor wire into (16 pin) case connector. 2. Install TSS
sensor wire into the locator.
4. CAUTION: Do not overstretch the retaining spring.
Install the transmission case (16 pin) electrical connector retaining spring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6064
5. Install the EPC and SSB solenoids.
6. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
7. Connect the SSA and SSC shift (SS) solenoid electrical connectors.
8. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors.
9. CAUTION: Excessive pressure may break the retaining pins.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6065
Install the wire harness guide and protector. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the wire harness
guide and protector.
10. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
11. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
12. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6066
13. Connect vehicle harness to transmission (16 pin) connector. Make sure lock is fully engaged.
14. Lower the vehicle.
15. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
16. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Specifications
Clutch Disc: Specifications
O.S. Diameter (approximate) 258 mm
I.S. Diameter (approximate) 173 mm
Facing Area sq. See note
288 Cm 45 sq. inch
Diaphragm spring Bellevile
Compressed thickness 7.8 mm
Lining material woven non-asbestos
flywheel runout 0.13 mm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Specifications > Page 6071
Clutch Disc: Service and Repair
Disc and Pressure Plate
Special Tool(s)
Removal
1. Remove the transmission.
2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed
evenly or permanent damage to the diaphragm
spring will occur resulting in complete clutch release.
Remove the bolts, clutch pressure plate and the clutch disc. ^
If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.
Installation
1. Lubricate the transmission input shaft pilot bearing.
^ Use front axle grease.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Specifications > Page 6072
2. Adjust the clutch pressure plate.
1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely. 2.
Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring
in this position. 3. Release the pressure on the fingers. The adjusting ring will stay in the reset
position.
3. Using the special tool, position the clutch disc on the flywheel.
4. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Using the special tool, align the clutch disc and the clutch pressure plate. Install the bolts and
tighten in a star pattern sequence.
5. Install the transmission.
^
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid >
Component Information > Specifications
Clutch Fluid: Specifications
Ford High Performance DOT3 Motor Vehicle Brake Fluid C6AZ-19542-AB ESA-M6C25-A, DOT3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 01-24-1 > Oct > 01
> Clutch - Pedal Stays On Floor/Does Not Disengage
Clutch Master Cylinder: Customer Interest Clutch - Pedal Stays On Floor/Does Not Disengage
Article No. 01-24-1
12/10/01
CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID
LEAK FROM HYDRAULIC CLUTCH LINE
FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER,
SUPER DUTY F SERIES, F-650, F-750
ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch
pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose
or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or
External Slave Cylinder.
ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External
Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the
proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or
External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure
for details.
SERVICE PROCEDURE
Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter
pins.
NOTE
MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE
SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND
F650-750.
NOTE
VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER)
REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED
ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150.
1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave
Cylinder (see previous notes) and the hydraulic line is disconnected or leaking.
2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder,
External Slave Cylinder and system bleed procedure.
3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External
Slave Cylinder.
4. Remove old quad seal from Master Cylinder and External Slave Cylinder.
5. Install new quad seal in Master Cylinder and External Slave Cylinder.
6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and
External Slave Cylinder.
7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External
Slave Cylinder).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 01-24-1 > Oct > 01
> Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6085
8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.
Labor Operation Claiming Chart
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7C522 39
OASIS CODES: 505200, 506000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 01-24-1
> Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage
Clutch Master Cylinder: All Technical Service Bulletins Clutch - Pedal Stays On Floor/Does Not
Disengage
Article No. 01-24-1
12/10/01
CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID
LEAK FROM HYDRAULIC CLUTCH LINE
FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER,
SUPER DUTY F SERIES, F-650, F-750
ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch
pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose
or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or
External Slave Cylinder.
ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External
Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the
proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or
External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure
for details.
SERVICE PROCEDURE
Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter
pins.
NOTE
MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE
SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND
F650-750.
NOTE
VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER)
REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED
ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150.
1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave
Cylinder (see previous notes) and the hydraulic line is disconnected or leaking.
2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder,
External Slave Cylinder and system bleed procedure.
3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External
Slave Cylinder.
4. Remove old quad seal from Master Cylinder and External Slave Cylinder.
5. Install new quad seal in Master Cylinder and External Slave Cylinder.
6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and
External Slave Cylinder.
7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External
Slave Cylinder).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 01-24-1
> Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6091
8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.
Labor Operation Claiming Chart
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7C522 39
OASIS CODES: 505200, 506000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Technical Service Bulletins > Page 6092
Clutch Master Cylinder: Specifications
Clutch master cylinder reservoir bolts 18 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Technical Service Bulletins > Page 6093
Clutch Master Cylinder: Service and Repair
1mClutch Master Cylinder/Reservoir
Special Tools
Removal and Installation
1. Raise and support the vehicle.
2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. 3. Lower the
vehicle.
4. Disconnect the Clutch Pedal Position (CPP) switch electrical connector.
5. Disconnect the clutch master cylinder rod from the clutch pedal arm.
^ Remove and discard the clutch master cylinder push rod bushing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Technical Service Bulletins > Page 6094
6. Remove the CPP switch.
^ Pinch the lock tabs and pull the clip forward.
^ Rotate and snap the CPP switch from the clutch master cylinder rod.
7. Remove the reservoir.
8. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 9. Unclip
the hydraulic line-to-frame retainer.
10. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, wash the surface with
water immediately.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Technical Service Bulletins > Page 6095
Unlock and remove the clutch master cylinder assembly. ^
Twist the clutch master cylinder clockwise 45 degrees to unlock it from the support bracket.
^ Remove the reservoir, the hydraulic line and the clutch master cylinder as an assembly.
^ Install a new clutch master cylinder push rod bushing.
11. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, wash the surface with
water immediately.
To install, reverse the removal procedure. ^
Bleed the clutch hydraulic system.
^ Rotate the clutch master cylinder 45 degrees counterclockwise.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Clutch Slave Cylinder: > 01-24-1 > Oct > 01 >
Clutch - Pedal Stays On Floor/Does Not Disengage
Clutch Slave Cylinder: Customer Interest Clutch - Pedal Stays On Floor/Does Not Disengage
Article No. 01-24-1
12/10/01
CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID
LEAK FROM HYDRAULIC CLUTCH LINE
FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER,
SUPER DUTY F SERIES, F-650, F-750
ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch
pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose
or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or
External Slave Cylinder.
ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External
Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the
proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or
External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure
for details.
SERVICE PROCEDURE
Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter
pins.
NOTE
MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE
SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND
F650-750.
NOTE
VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER)
REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED
ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150.
1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave
Cylinder (see previous notes) and the hydraulic line is disconnected or leaking.
2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder,
External Slave Cylinder and system bleed procedure.
3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External
Slave Cylinder.
4. Remove old quad seal from Master Cylinder and External Slave Cylinder.
5. Install new quad seal in Master Cylinder and External Slave Cylinder.
6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and
External Slave Cylinder.
7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External
Slave Cylinder).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Clutch Slave Cylinder: > 01-24-1 > Oct > 01 >
Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6104
8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.
Labor Operation Claiming Chart
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7C522 39
OASIS CODES: 505200, 506000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Slave Cylinder: > 01-24-1
> Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage
Clutch Slave Cylinder: All Technical Service Bulletins Clutch - Pedal Stays On Floor/Does Not
Disengage
Article No. 01-24-1
12/10/01
CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID
LEAK FROM HYDRAULIC CLUTCH LINE
FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER,
SUPER DUTY F SERIES, F-650, F-750
ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch
pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose
or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or
External Slave Cylinder.
ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External
Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the
proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or
External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure
for details.
SERVICE PROCEDURE
Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter
pins.
NOTE
MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE
SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND
F650-750.
NOTE
VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER)
REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED
ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150.
1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave
Cylinder (see previous notes) and the hydraulic line is disconnected or leaking.
2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder,
External Slave Cylinder and system bleed procedure.
3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External
Slave Cylinder.
4. Remove old quad seal from Master Cylinder and External Slave Cylinder.
5. Install new quad seal in Master Cylinder and External Slave Cylinder.
6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and
External Slave Cylinder.
7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External
Slave Cylinder).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Slave Cylinder: > 01-24-1
> Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6110
8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.
Labor Operation Claiming Chart
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7C522 39
OASIS CODES: 505200, 506000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Technical Service Bulletins > Page 6111
Clutch Slave Cylinder: Specifications
Clutch slave cylinder bolts 15 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Technical Service Bulletins > Page 6112
Clutch Slave Cylinder: Service and Repair
Slave Cylinder
Removal
1. Remove the transmission.
2. NOTE: Inspect the clutch housing for traces of fluid. If brake fluid is visible, install a new clutch
slave cylinder.
Remove the clutch slave cylinder. 1. Remove the bolts. 2. Remove the clutch slave cylinder.
3. Inspect the clutch slave cylinder for the following:
^ Worn or damaged boot.
^ Leaking fluid.
^ Worn or damaged bearing.
4. Inspect the clutch release bearing as follows:
^ Rotate the outer race while applying pressure. If the bearing rotation is rough, install a new clutch
slave cylinder.
^ Inspect for wear or damage. ^
If wear pattern is continuous (not segmented) and the wear appears to be deep in bearing face,
install a new clutch slave cylinder.
Installation
1. To install, reverse the removal procedure.
^ Position the clutch slave cylinder to the transmission and install the bolts.
2. Install the transmission. 3. Bleed the clutch hydraulic system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 01-24-1 > Oct > 01 >
Clutch - Pedal Stays On Floor/Does Not Disengage
Hydraulic Hose: Customer Interest Clutch - Pedal Stays On Floor/Does Not Disengage
Article No. 01-24-1
12/10/01
CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID
LEAK FROM HYDRAULIC CLUTCH LINE
FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER,
SUPER DUTY F SERIES, F-650, F-750
ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch
pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose
or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or
External Slave Cylinder.
ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External
Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the
proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or
External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure
for details.
SERVICE PROCEDURE
Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter
pins.
NOTE
MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE
SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND
F650-750.
NOTE
VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER)
REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED
ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150.
1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave
Cylinder (see previous notes) and the hydraulic line is disconnected or leaking.
2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder,
External Slave Cylinder and system bleed procedure.
3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External
Slave Cylinder.
4. Remove old quad seal from Master Cylinder and External Slave Cylinder.
5. Install new quad seal in Master Cylinder and External Slave Cylinder.
6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and
External Slave Cylinder.
7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External
Slave Cylinder).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 01-24-1 > Oct > 01 >
Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6121
8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.
Labor Operation Claiming Chart
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7C522 39
OASIS CODES: 505200, 506000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 01-24-1 >
Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage
Hydraulic Hose: All Technical Service Bulletins Clutch - Pedal Stays On Floor/Does Not Disengage
Article No. 01-24-1
12/10/01
CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID
LEAK FROM HYDRAULIC CLUTCH LINE
FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER,
SUPER DUTY F SERIES, F-650, F-750
ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch
pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose
or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or
External Slave Cylinder.
ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External
Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the
proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or
External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure
for details.
SERVICE PROCEDURE
Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter
pins.
NOTE
MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE
SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND
F650-750.
NOTE
VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER)
REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED
ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150.
1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave
Cylinder (see previous notes) and the hydraulic line is disconnected or leaking.
2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder,
External Slave Cylinder and system bleed procedure.
3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External
Slave Cylinder.
4. Remove old quad seal from Master Cylinder and External Slave Cylinder.
5. Install new quad seal in Master Cylinder and External Slave Cylinder.
6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and
External Slave Cylinder.
7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External
Slave Cylinder).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 01-24-1 >
Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6127
8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.
Labor Operation Claiming Chart
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7C522 39
OASIS CODES: 505200, 506000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Technical Service Bulletins > Page 6128
Hydraulic Hose: Tools and Equipment
Clutch Line Fork
AST tool# 8008
Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This
tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford
Aerostar, Bronco II, Explorer, F150 and Ranger.
- For R and R of Hydraulic Clutch Lines
- Applicable to Ford Models with Manual Transmissions
- Steel Construction
- Black-Oxide Finish
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information >
Specifications
Clutch Pedal Assembly: Specifications
Clutch pedal type suspended
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information >
Specifications > Page 6132
Clutch Pedal Assembly: Service and Repair
Clutch Pedal
Removal and Installation
NOTE: The clutch pedal is serviced with the brake pedal as an assembly only.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service
and Repair
Pilot Bearing: Service and Repair
Bearing
Special Tools
Special Tool(s)
Removal
1. Using the special tool, remove the transmission input shaft pilot bearing.
2. Inspect the transmission input shaft pilot bearing for:
^ misalignment and looseness in the flywheel.
^ needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration.
^ seal leakage.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service
and Repair > Page 6139
1. NOTE: The transmission input shaft pilot bearing can only be installed with the seal facing the
transmission. The transmission input shaft pilot
bearing is pregreased and does not require additional lubrication. A new transmission input shaft
pilot bearing must be installed whenever it is removed.
Using a soft-face hammer and the special tool, install the transmission input shaft pilot bearing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications
Pressure Plate: Specifications
Clutch pressure plate bolts 24 ft. lbs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications > Page 6143
Pressure Plate: Service and Repair
"For information regarding this component please refer to Clutch Disc MT Service and Repair"
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case
Differential Case: Service and Repair Case
Differential Case
Special Tools
Special Tool(s)
Removal
1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and inspect the
parts for wear and damage.
3. Rotate the differential assembly to check for roughness indicating bearing/gear damage.
4. NOTE: There is a space between the anti-lock speed sensor ring and the differential ring gear
for measuring the differential ring gear backface
runout.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6149
Using a suitable dial indicator and the special tool, measure and note the differential ring gear
backface runout.
5. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. Always
install the bearing caps in their identical locations
and positions.
Remove the bearing caps. 1. Remove the bolts. 2. Remove the bearing caps.
6. WARNING: Do not allow the differential assembly to fall.
CAUTION: Place a wood block between the pry bar and the differential housing to protect the
machined surface from damage.
Using a pry bar and a wood block, remove the differential assembly from the differential housing.
7. Remove the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6150
8. CAUTION:
^ Do not damage the differential ring gear bolt hole threads.
^ If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor
ring during installation.
Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the
anti-lock speed sensor ring.
9. If the differential ring gear backface runout measurement, taken at the beginning of this
procedure, did not exceed the specification, proceed to the
appropriate procedure as necessary: Drive Pinion, Differential Case and Ring Gear-Conventional
or Differential Case and Ring Gear-Traction-Lok, or to Installation in this procedure. If the
differential ring gear backface runout measurement, taken at the beginning of this procedure,
exceeded the specification, the cause may be a warped differential ring gear, differential
case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout.
10. Position the differential assembly, including the differential bearing cups and differential bearing
shims, in the differential housing. Install the
bearing caps and the bolts.
11. Position the special tool.
1. Rotate the differential case to verify that the differential bearings have seated correctly. 2.
Position the special tool.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6151
12. Measure and note the differential case runout.
^ If the runout does not exceed the specification, install a new differential ring gear and pinion.
^ If the runout exceeds the specification, the differential ring gear is true and the concern is due to
either differential case/differential bearing damage. Proceed as follows.
13. Using the special tools, remove the differential bearings.
14. Using the special tool, install the new differential bearings.
15. Position the differential assembly, including the differential bearing cups and differential bearing
shims in the differential housing. Tighten bearing
caps to specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6152
16. Position the special tool.
1. Rotate the differential case to verify that the differential bearings have seated correctly. 2.
Position the special tool.
17. Measure the differential case runout.
^ If the runout does not exceed the specification, use the new differential bearings for assembly.
^ If the runout exceeds the specification, install a new differential case.
Installation
All vehicles
1. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and
the tab on the anti-lock speed sensor ring.
Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align
the bolt holes by starting two bolts through the holes in the differential case and the differential ring
gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the
differential case.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6153
2. Install the bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification
WSK-M2G349-A1 to the bolt threads.
3. With the pinion depth set and pinion installed, place the differential assembly in the differential
housing.
4. Install a differential bearing shim on the left side.
5. CAUTION: Always install the bearing caps in their identical locations and positions.
NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats
correctly.
Install the left bearing cap and loosely install the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6154
6. Install progressively larger differential bearing shims on the right side until the largest shim
selected is installed by hand.
7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
8. Rotate the differential case to make sure it turns freely.
Measuring backlash
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6155
9. Using the special tools, measure and note the differential ring gear backlash.
^ If backlash is within the specification, refer to Backlash within specification. The specification
shown is the full allowable range.
^ If a zero backlash condition occurs, refer to Zero backlash.
^ If backlash is not within the specification, refer to Backlash not within specification.
10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51
mm (0.020 inch) from the LH side to allow
backlash indication. Measure the backlash.
11. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a
thinner shim accordingly.
^ If backlash is not within the specification,increase the thickness of one differential bearing shim
and decrease the thickness of the other differential bearing shim by the same amount.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6156
12. Rotate the differential assembly several times to verify that the differential bearings seated
correctly.
13. Using the special tools, recheck the backlash.
^ If backlash is within the specification, refer to Measuring backlash.
^ Backlash within specification in this procedure. If backlash is not within the specification, repeat
Backlash not within specification.
^ The specification shown is the full allowable range.
Backlash within specification
14. Remove the bolts and the bearing caps.
15. To establish differential bearing preload, increase both left and right differential bearing shim
sizes by the specification shown.
16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates
freely.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6157
17. Install the bearing caps and bolts.
18. Using the special tools, recheck the backlash.
^ The specification shown is the full allowable range.
19. Install the axle shafts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6158
Differential Case: Service and Repair Differential Case and Ring Gear -Conventional
Differential Case and Ring Gear-Conventional
Special Tools
Special Tool(s)
Disassembly
1. Remove the differential assembly from the differential housing.
2. Remove the bolts.
3. CAUTION:
^ Do not damage the differential ring gear bolt hole threads.
^ If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor
ring during assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6159
Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the
anti-lock speed sensor ring.
4. Using the special tools, remove the differential bearings, if necessary.
5. Remove the bolt.
6. Remove the differential pinion shaft.
7. Rotate and remove the differential pinion gears and differential pinion thrust washers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6160
8. Remove the differential side gears and differential side gear thrust washers.
Assembly
1. Lubricate the differential side gear thrust washers and the differential side gear journals.
^ Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C197-A.
2. Position the differential side gear thrust washers on the differential side gears.
3. Position the differential side gear and thrust washer assemblies in the differential case.
4. Lubricate and assemble the differential pinion thrust washers and differential pinion gears.
^ Use SAL 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C197-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6161
5. Engage the differential pinion gears opposite the differential side gears.
6. Rotate the differential pinion gears to align with the differential pinion shaft bore.
7. Insert the differential pinion shaft.
^ Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case.
8. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer
EOAZ-19554-AA or equivalent meeting Ford specification
WSK-M2G351-A5 prior to installation.
Install a new bolt finger-tight.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6162
9. Using the special tool, install the new differential bearings.
10. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange
and the tab on the anti-lock speed sensor ring.
Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align
the bolt holes by starting two bolts through the holes in the differential case and the differential ring
gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the
differential case.
11. Install the bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification
WSK-M2G349-A1 to the bolt threads.
12. Install the differential assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6163
Differential Case: Service and Repair Differential Case and Ring Gear -Traction-LOK
Differential Case and Ring Gear-Traction-Lok
Special Tool(s)
Disassembly
1. Remove the differential assembly from the differential housing.
2. Remove the bolts.
3. CAUTION:
^ Do not damage the bolt hole threads.
^ If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor
ring during assembly.
Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the
anti-lock speed sensor ring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6164
4. Using the special tools, remove the differential bearings.
5. Remove the bolt and remove the differential pinion shaft.
6. WARNING: Due to the spring tension, use care when removing the differential clutch spring.
Failure to follow these instruction can
result in personal injury.
Remove the differential clutch spring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6165
7. Remove the differential gears.
1. Remove the two differential pinion gears. 2. Remove the two differential side gears. 3. Remove
the two differential pinion thrust washers.
8. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble
them in the same sequence.
Separate the differential clutch packs and shims from the differential side gears and tag them ^
Clean and inspect the remaining differential components for wear and damage and install new
parts as necessary.
9. CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the
components only with a clean, lint-free cloth.
Clean and inspect the differential clutch packs for wear and damage and install new parts as
necessary.
Assembly
1. CAUTION: 118 ml (4 on) of the Additive Friction Modifier must be used in the axle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6166
Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes. ^
Use Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification
EST-M2C11-A.
2. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the other.
Assemble the differential clutch packs (without the shims) on their respective differential side gear.
3. CAUTION: Use the correct mandrel with the special tool.
Place the base portion of the special tool in a vise. Install the differential side gear and differential
clutch pack (without the shim) on the tool.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6167
4. Position the special tool hand-tight on top of the differential clutch pack.
5. Install the special tool over the disc and differential clutch pack.
6. Install the nut.
7. Select and insert the thickest feeler gauge blade that will enter between the tool and the
differential clutch pack. The reading will be the thickness
of the new clutch shim.
8. Remove the special tool from the differential clutch pack and differential side gear assembly. 9.
Install the shim(s) on the differential clutch pack and differential side gear assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6168
10. Install the differential side gear assemblies in the differential case.
11. Install the differential pinion gear and differential pinion thrust washer assemblies in the
differential case.
12. Using a soft-faced hammer, install the differential clutch spring.
13. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer
EOAZ-19554-AA or equivalent meeting Ford specification
WSK-M2G351-A5 prior to installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6169
Install the differential pinion shaft and install a new bolt finger-tight.
14. Mount the differential case and the special tool in a vise. Using the special tool, check the
torque necessary to rotate one differential side gear.
^ If reusing the original clutch plates, the initial minimum break-away torque must be no less than
the specification. The minimum rotating torque necessary to keep the differential side gear turning
with new clutch plates may vary.
15. Using the special tool, install the differential bearings.
16. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange
and the tab on the anti-lock speed sensor ring.
Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align
the bolt holes by starting two bolts through the holes in the differential case and the differential ring
gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the
differential case.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Case > Page 6170
17. Install the bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification
WSK-M2G349-A1 to bolt threads.
18. Install the differential assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Service and Repair
Differential Cover: Service and Repair
Differential Housing Cover
Removal
1. Raise and support the vehicle.
2. NOTE: Empty the lubricant into a clean container for reuse.
Remove the differential housing cover. 1. Remove the bolts and drain the lubricant from the
differential housing. 2. Remove the differential housing cover.
Installation
1. CAUTION: The machined surfaces on the differential housing and the differential housing cover
must be clean and free of oil before applying
the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to
prevent contamination.
Clean the gasket mating surfaces.
2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it
will be necessary to apply new sealant.
Apply a continuous bead of sealant to the differential housing cover. ^
Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification
ESB-M4G92-A.
3. NOTE: If possible, allow one hour before filling the axle with lubricant to allow the silicone
sealant to cure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Service and Repair > Page 6174
Install the differential housing cover. 1. Position the differential housing cover. 2. Install the bolts.
4. CAUTION: For Traction-Lok(R) axles, first fill the rear axle with 118 ml (4 oz) of Additive Friction
Modifier C8AZ-19B546-A or equivalent
meeting Ford specification EST-M2C118-A.
NOTE: Service refill capacities are determined by filling the rear axle to the level shown.
Fill the rear axle with 2.4 liters (5.0 pints) of lubricant and install the fill plug. ^
For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
5. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair
Differential Axle Housing: Service and Repair
Axle Housing
Removal and Installation
1. NOTE: Make sure the parking brake control is fully released.
Release the tension on the front parking brake cable and conduit. 1. Pull on the front parking brake
cable and conduit until the parking brake pedal moves. 2. Insert a suitable retainer, such as a
5/32-inch drill bit, into the parking brake control to hold it in place so that the front parking brake
cable and
conduit stays slack.
2. Raise and support the vehicle. 3. Remove the axle shafts.
4. Mark the driveshaft flange and pinion flange for correct alignment during installation.
5. CAUTION: The driveshaft centering socket yoke fits tightly on the rear pinion flange pilot. Never
hammer on the driveshaft or any of its
components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool
to disconnect the yoke from the flange.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 6178
Remove the four driveshaft retainer bolts and disconnect the driveshaft. Wire the driveshaft out of
the way.
6. NOTE:
^ Do not disconnect the brake lines from the brake hose junction block.
^ Explorer Sport Trac is shown. Explorer Sport brake hose junction block is located on the LH side
of the differential housing.
Disconnect the brake hose junction block from the differential housing.
7. Disconnect the vent hose.
8. Disconnect the parking cable and conduit at the parking brake lever, if so equipped.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 6179
9. Disconnect the vehicle speed sensor, if so equipped.
10. CAUTION: Pull the brake lines from the retaining clips.
Remove the brake system. ^
Disconnect the rear brake drum backing plates, if equipped, and wire them out of the way.
^ Remove the rear brake discs and the rear disc brake calipers and wire the rear disc brake
calipers aside.
11. Position a suitable jack under the rear axle housing and strap it securely in place.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 6180
12. Disconnect the rear stabilizer bar at the links.
13. Remove the lower shock absorber nuts and bolts, and the front dampener shock absorber nuts
and bolts, if equipped.
14. Remove the rear axle U-bolt assembly.
15. CAUTION: Be careful of obstructions and of causing damage to vehicle components when
performing this step.
Raise the differential housing off the rear springs and manipulate the differential housing from the
vehicle.
16. CAUTION:
^ Be sure to align the driveshaft flange and the pinion flange index-marks.
^ The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To ensure that
the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 6181
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
Refill .....................................................................................................................................................
............................................................. 5.5-5.8 pints
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 6186
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Conventional ........................................................................................................................................
..................................................................... 80W-90 Traction-Lok .....................................................
...................................................................................................................................... 75W-140
Synthetic
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Specifications > Dana
Pinion Bearing: Specifications
Pinion Bearing Preload (New Pinion Bearings) 15 - 30 in.lb
Pinion bearing preload (original pinion Bearings) See note
the reading must be 0.56 nm (5 lb-in) more than the intial reading taken during
disassembly.
Bolt Retaining The Universal Joint Retainer To The Pinion Flange 14 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Specifications > Dana > Page 6191
Pinion Bearing: Specifications
Pinion Bearing Preload (Used Pinion Bearings) 8 - 14 in.lb
Pinion Bearing Preload (New Pinion Bearings) 16 - 29 in.lb
Differential Bearing Cap Bolt 77 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair
Pinion Flange: Service and Repair
Drive Pinion Flange
Special Tools
Special Tool(s)
Removal
1. Remove the rear wheel and tire assemblies.
2. CAUTION: Remove the brake drums to prevent brake drag during drive pinion bearing preload
adjustment.
Remove the brake system.
3. CAUTION: Index-mark the driveshaft flange and pinion flange for correct alignment during
installation.
Remove the four bolts.
4. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot.
Never hammer on the driveshaft or any of its
components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool
to disconnect the yoke from the flange.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 6195
Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear axle
pinion flange.
5. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain
rotation of the pinion through several revolutions.
6. CAUTION: Discard the nut after removing it. Install a new nut during installation.
Use the special tool to hold the pinion flange while removing the nut.
7. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 6196
8. Using the special tool, remove the pinion flange.
Installation
1. Lubricate the pinion flange splines.
^ For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
2. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
3. Using the special tool, install the pinion flange.
4. Position the new nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 6197
5. CAUTION:
^ Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce
preload, install a new collapsible spacer and nut.
^ Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.
Use the special tool to hold the pinion flange while tightening the nut. ^
Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take
frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound)
torque wrench.
^ If the preload recorded prior to disassembly is lower than the specification for used bearings, then
tighten the nut to specification. If the preload recorded prior to disassembly is higher than the
specification for used bearings, then tighten the nut to the original reading as recorded.
6. CAUTION: Align the Index-marks.
Install the four bolts.
7. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To
ensure that the yoke seats squarely on the
flange, tighten the bolts evenly in a cross pattern as shown.
Tighten to specification.
8. Install the bake system. 9. Install the rear wheel and tire assemblies.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair
Pinion Gear: Service and Repair
Drive Pinion
Special Tools(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 6201
Removal
1. Remove the differential case.
2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through
several revolutions prior to removing the pinion
flange.
Remove the pinion flange.
3. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a
hammer.
4. Using gripping pliers and a hammer, remove the rear axle drive pinion seal. 5. Remove the rear
axle drive pinion shaft oil slinger.
6. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the front pinion
bearing and remove it through the rear of the
differential housing.
7. Remove the drive pinion collapsible spacer and discard it.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 6202
8. Using the special tool and a suitable press, remove the pinion bearing.
9. NOTE: Do not remove the pinion bearing cups from the differential housing unless the cups are
damaged.
Using the special tools, remove the outer pinion bearing cup.
10. Using the special tools, remove the inner pinion bearing cup.
Installation
1. NOTE: This step and the following step show the preferred method for installing the pinion
bearing cups. An alternate method is shown
following these two steps.
Position the special tools and the inner and outer pinion bearing cups in their respective bores.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 6203
1. After placing the inner and outer pinion bearing cups in their bores, place the special tool on the
inner pinion bearing cup. 2. Place the special tool on the outer pinion bearing cup. 3. Install the
special tool.
2. Tighten the special tool to seat the pinion bearing cups into their bores.
3. NOTE: This step and the following step are alternate methods for installing the pinion bearing
cups. Carry out these two steps if pinion bearing
cup installation was not done in the previous steps.
Using the special tools, drive the outer pinion bearing cup into the differential housing.
4. Using the special tools, drive the inner pinion bearing cup into the differential housing.
5. CAUTION: Always install new pinion bearings when installing new pinion bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the
cup, remove and reseat the cup.
Check that the cups have seated correctly in their bores.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 6204
6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
Assemble and position the following in the differential housing.
7. NOTE: This step duplicates final pinion bearing preload.
Tighten the special tool to the specification shown.
8. NOTE: Offset the special tool to obtain an accurate reading.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 6205
Rotate the special tool several half-turns to make sure the pinion bearings seat correctly and
position the special tool as shown.
9. Install the special tool.
1. Position the special tool. 2. Install the bearing caps. 3. Install the bolts.
10. CAUTION:
^ Use only flat, clean drive pinion bearing adjustment shims.
^ Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to
force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim
selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection. ^
After determining the correct shim thickness, remove the special tools.
11. Position the correct thickness drive pinion bearing adjustment shim and the pinion bearing on
the drive pinion. Using a suitable press and the
special tools, press the pinion bearing until it seats firmly on the pinion.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 6206
12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem
shoulder.
13. CAUTION: Installation without the correct tool can result in early seal failure.
Install a new rear axle drive pinion seal. 1. Install the front pinion bearing. 2. Install the rear axle
drive pinion shaft oil slinger. 3. Install the rear axle drive pinion seal on the special tool.
14. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the
seal and install a new seal.
NOTE: Coat the rear axle drive pinion seal lips with Premium Long-Life Grease XG-1-C or
equivalent meeting Ford specification ESA-M1C75-B.
Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal
into place.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 6207
15. From inside the differential housing, install the drive pinion assembly (drive pinion, shims,
bearing, and the collapsible spacer) into the carrier
bore.
16. Lubricate the pinion flange splines.
^ For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R)axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
17. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
18. Using the special tool, install the pinion flange.
19. Position the new nut.
20. CAUTION:
^ Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce
preload, install a new collapsible spacer and nut.
^ Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 6208
Use the special tool to hold the pinion flange while tightening the nut. ^
Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent
pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
^ For new pinion bearings, tighten the nut to specification.
^ For used pinion bearings, if the preload recorded prior to disassembly is lower than the
specification for used bearings, then tighten the nut to specification.
^ For used pinion bearings, if the preload recorded prior to disassembly is higher than the
specification for used bearings, then tighten the nut to the original reading as recorded.
21. Install the differential case in the differential housing.
22. CAUTION: Be sure to align the driveshaft flange and the pinion flange index-marks.
Install the four bolts.
23. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot.
To ensure that the yoke seats squarely on the
flange, tighten the bolts evenly in a cross pattern as shown.
Tighten to specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Differential Case and Ring Gear-Conventional
Ring Gear: Service and Repair Differential Case and Ring Gear-Conventional
Differential Case and Ring Gear-Conventional
Special Tools
Special Tool(s)
Disassembly
1. Remove the differential assembly from the differential housing.
2. Remove the bolts.
3. CAUTION:
^ Do not damage the differential ring gear bolt hole threads.
^ If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor
ring during assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6213
Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the
anti-lock speed sensor ring.
4. Using the special tools, remove the differential bearings, if necessary.
5. Remove the bolt.
6. Remove the differential pinion shaft.
7. Rotate and remove the differential pinion gears and differential pinion thrust washers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6214
8. Remove the differential side gears and differential side gear thrust washers.
Assembly
1. Lubricate the differential side gear thrust washers and the differential side gear journals.
^ Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C197-A.
2. Position the differential side gear thrust washers on the differential side gears.
3. Position the differential side gear and thrust washer assemblies in the differential case.
4. Lubricate and assemble the differential pinion thrust washers and differential pinion gears.
^ Use SAL 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C197-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6215
5. Engage the differential pinion gears opposite the differential side gears.
6. Rotate the differential pinion gears to align with the differential pinion shaft bore.
7. Insert the differential pinion shaft.
^ Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case.
8. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer
EOAZ-19554-AA or equivalent meeting Ford specification
WSK-M2G351-A5 prior to installation.
Install a new bolt finger-tight.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6216
9. Using the special tool, install the new differential bearings.
10. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange
and the tab on the anti-lock speed sensor ring.
Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align
the bolt holes by starting two bolts through the holes in the differential case and the differential ring
gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the
differential case.
11. Install the bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification
WSK-M2G349-A1 to the bolt threads.
12. Install the differential assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6217
Ring Gear: Service and Repair Differential Case and Ring Gear-Traction-LOK
"For information regarding this component please refer to Differential Case Service and Repair"
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair
Seals and Gaskets: Service and Repair
Drive Pinion Seal
Special Tools
Special Tool(s)
Removal
1. Remove the pinion flange.
2. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a
hammer.
3. Using gripping pliers and a hammer, remove the seal.
Installation
1. Coat the new rear axle drive pinion seal lips with lubricant.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
2. CAUTION:
^ Installation without the correct tool can result in early seal failure.
^ If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and
install a new seal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Page 6221
Using the special tool, install the rear axle drive pinion seal.
3. Install the pinion flange.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Locations
Axle Shaft: Locations
Front Drive Halfshaft and Joint Assembly
Part 1 of 2
Part 2 of 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Locations > Page 6227
Axle Shaft: Service and Repair
Axle Shaft
Removal
NOTE: In this procedure, drum brake is shown. Disc brake is similar.
1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Remove the
brake system.
^ Remove the brake drum.
^ Remove the brake discs and rear disc brake calipers.
4. Remove the differential housing cover and drain the lubricant.
5. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer
EOAZ-19554-AA or equivalent meeting Ford specification
WSK-M2G351-A5 prior to installation.
Remove the differential pinion shaft. 1. Remove and discard the bolt. 2. Remove the differential
pinion shaft.
6. CAUTION: Do not damage the rubber O-ring in the U-washer groove.
Remove the U-washer. 1. Push the axle shaft inboard. 2. Remove the U-washer.
7. CAUTION: Do not damage the wheel bearing oil seal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Locations > Page 6228
Remove the axle shaft.
Installation
1. Lubricate the lip of the wheel bearing oil seal.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
2. CAUTION: Do not damage the wheel bearing oil seal.
Install the axle shaft.
3. CAUTION: Do not damage the rubber O-ring in the U-washer groove.
Install the U-washer. 1. Position the U-washer on the button end of the axle shaft. 2. Pull the axle
shaft outward.
4. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer
EOAZ-19554-AA or equivalent meeting Ford specification
WSK-M2G351-A5 prior to installation.
Install the differential pinion shaft. 1. Align the bolt hole in the differential pinion shaft with the bolt
hole in the case. 2. Install the new bolt.
5. Install the brake system.
^ Install the brake drum.
^ Install the brake discs and calipers.
6. Install the differential housing cover and fill the differential housing with the specified lubricant. 7.
Install the rear wheel and tire assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Locations > Page 6229
8. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Seals and Gaskets: Service and Repair Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Special Tools
Special Tool(s)
Removal
1. Remove the axle shaft.
2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with
foreign material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.
Installation
1. Lubricate the new rear wheel bearing.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 6234
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 6235
Seals and Gaskets: Service and Repair Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Special Tool(s)
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 6236
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Specifications
Wheel Bearing: Specifications
- Lubricate the new rear wheel bearing. ^
For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
- Lubricate the lip of the new wheel bearing oil seal. ^
Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Specifications > Page 6240
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of
the following actions.
^ On 4x2 vehicles, adjust the front wheel bearings.
^ On 4x4 vehicles, install a new wheel hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Ford
Wheel Bearing: Service and Repair Ford
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Special Tools
Special Tool(s)
Removal
1. Remove the axle shaft.
2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with
foreign material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.
Installation
1. Lubricate the new rear wheel bearing.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Ford > Page 6243
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Special Tool(s)
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Ford > Page 6244
NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
- Tighten the spindle nut while rotating the brake disc and hub.
- Loosen the spindle nut.
- Tighten the spindle nut while rotating the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-2 > Nov > 02 > A/T - 5R55E
1st/2nd Gear Whining Noise
Drive/Propeller Shaft: Customer Interest A/T - 5R55E 1st/2nd Gear Whining Noise
Article No. 02-22-2
11/11/02
^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH
5R55E TRANSMISSION AND 4.0L ENGINE ONLY
^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES
EQUIPPED WITH 4.0L ENGINE ONLY
FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER
ISSUE
Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002,
equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of
noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary
assemblies and/or the driveshaft.
ACTION
Verify that only these conditions exist and no DTCs are present. If other conditions are present and
DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and
only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using
the chart provided, select the parts that need to be replaced.
NOTE
IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED.
SERVICE PROCEDURE
Gear Whine Service Procedure
1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need
to be replaced, refer to Application and Component replacement chart shown.
2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate
Workshop Manual section for driveshaft removal/replacement.
3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual,
Section 307-01, Transmission Removal procedures, remove the transmission.
4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement
chart.
NOTE
REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED.
DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS
ARE NOT REQUIRED FOR THIS PROCEDURE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-2 > Nov > 02 > A/T - 5R55E
1st/2nd Gear Whining Noise > Page 6258
NOTE
BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE.
5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly
(7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond
the Reverse Planetary assembly.
6. Using the appropriate Transmission Assembly procedures, assemble the transmission and
install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service
Forward Planetary Assembly (XL2Z-7A398-AA).
7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission
Installation procedures, install transmission.
8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the
appropriate application listed.
9. Verify repair. Clear DTCs.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
022202A Replace Transmission 5.5 Hrs.
Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission
5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2
022202B Replace Transmission 7.0 Hrs.
Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission
5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4
022202C Replace Driveshaft 0.4 Hr.
Only 2002-2003 Explorer Sport Trac 4x2
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A398 42
OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-2 > Nov > 02 > A/T - 5R55E
1st/2nd Gear Whining Noise > Page 6259
DISCLAIMER
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-22-2 > Nov > 02 > A/T 5R55E 1st/2nd Gear Whining Noise
Drive/Propeller Shaft: All Technical Service Bulletins A/T - 5R55E 1st/2nd Gear Whining Noise
Article No. 02-22-2
11/11/02
^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH
5R55E TRANSMISSION AND 4.0L ENGINE ONLY
^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES
EQUIPPED WITH 4.0L ENGINE ONLY
FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER
ISSUE
Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002,
equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of
noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary
assemblies and/or the driveshaft.
ACTION
Verify that only these conditions exist and no DTCs are present. If other conditions are present and
DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and
only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using
the chart provided, select the parts that need to be replaced.
NOTE
IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED.
SERVICE PROCEDURE
Gear Whine Service Procedure
1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need
to be replaced, refer to Application and Component replacement chart shown.
2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate
Workshop Manual section for driveshaft removal/replacement.
3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual,
Section 307-01, Transmission Removal procedures, remove the transmission.
4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement
chart.
NOTE
REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED.
DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS
ARE NOT REQUIRED FOR THIS PROCEDURE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-22-2 > Nov > 02 > A/T 5R55E 1st/2nd Gear Whining Noise > Page 6265
NOTE
BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE.
5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly
(7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond
the Reverse Planetary assembly.
6. Using the appropriate Transmission Assembly procedures, assemble the transmission and
install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service
Forward Planetary Assembly (XL2Z-7A398-AA).
7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission
Installation procedures, install transmission.
8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the
appropriate application listed.
9. Verify repair. Clear DTCs.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
022202A Replace Transmission 5.5 Hrs.
Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission
5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2
022202B Replace Transmission 7.0 Hrs.
Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission
5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4
022202C Replace Driveshaft 0.4 Hr.
Only 2002-2003 Explorer Sport Trac 4x2
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A398 42
OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-22-2 > Nov > 02 > A/T 5R55E 1st/2nd Gear Whining Noise > Page 6266
DISCLAIMER
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set
Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON
DTCB2607 May Be Set
Article No. 01-6-1
04/02/01
^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
FORD: 2001 EXPLORER
ISSUE
The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607
may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp
may remain on or may illuminate intermittently. This may be due to the ABS module remaining
active when the engine is cranked and both blower motors are on.
ACTION
Replace the ABS module with an updated module if existing module is the original design, and
check for proper circuit grounding. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
It the ABS lamp is on intermittently:
1. Replace the ABS module.
a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Test drive vehicle to verify repair.
If the ABS lamp is on continuously:
1. Replace the ABS module.
a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 3.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6272
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
3. Verify if the vehicle is a 4X4 or 4X2.
^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded.
^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary.
4. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 5.
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 301000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6278
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
3. Verify if the vehicle is a 4X4 or 4X2.
^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded.
^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary.
4. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 5.
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 301000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Page 6279
Drive/Propeller Shaft: Diagrams
Driveshaft Rear
Part 1 of 2
Part 2 of 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front
Drive/Propeller Shaft: Service and Repair Front
Driveshaft-Front
Removal and Installation
1. With the vehicle in neutral, raise and support the vehicle.
2. Index-mark the front axle pinion flange and the front driveshaft.
3. Remove the skid plate.
4. Index-mark the front output shaft assembly and the front driveshaft Constant Velocity (CV) joint.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front > Page 6282
5. Remove and discard the bolts and washers.
6. Remove and discard the bolts and universal joint retainers.
7. CAUTION:
^ Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the
driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
^ Tape the bearing cups to the driveshaft to prevent them from falling off of he spider.
NOTE: The front driveshaft CV joint is not repairable.
Remove the driveshaft.
8. NOTE:
^ Install the driveshaft with new bolts and washers and new bolts and universal joint retainers. If
new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer
E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5.
^ When installing the front driveshaft, always connect it to the axle first and then connect it to the
transfer case.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Front > Page 6283
Drive/Propeller Shaft: Service and Repair Rear
Driveshaft-Rear
Removal and Installation
1. With the vehicle in neutral, raise and support the vehicle.
2. Index-mark the driveshaft flange and the rear axle pinion flange.
3. Remove the driveshaft.
1. Remove and discard the four bolts, and disconnect the driveshaft from the rear axle pinion
flange. 2. Lower the driveshaft, and slide it rearward off of the transmission output shaft.
^ Plug the extension housing to prevent fluid loss.
4. NOTE: Install the driveshaft with new bolts. If new bolts are not available, coat the threads of the
original bolts with Threadlock and Sealer
EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Service and Repair
Slip Yoke: Service and Repair
Driveshaft Slip Yoke
Special Tools
Special Tool(s)
Disassembly
1. Remove the driveshaft.
2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture.
Remove the driveshaft slip-yoke boot. 1. Index-mark the driveshaft and the driveshaft slip-yoke. 2.
Cut and discard the driveshaft slip-yoke boot clamps. 3. Separate the driveshaft slip-yoke from the
splined stub shaft, and remove the driveshaft slip-yoke boot.
^ Inspect the driveshaft slip-yoke boot for damage and discard it if necessary.
3. Inspect the lubricant for contamination. If contaminated, inspect the stub shaft and driveshaft
slip-yoke for wear. Discard the driveshaft if
necessary.
Assembly
1. Position the small driveshaft slip-yoke boot clamp on the splined stub shaft.
2. Position the end of the driveshaft slip-yoke boot with the smaller diameter opening on the splined
stub shaft and slide the boot on the shaft as far as
it will travel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Service and Repair > Page 6287
3. Using the special tool, crimp the small driveshaft slip-yoke boot clamp.
4. CAUTION: Align the index marks made during disassembly.
Install the driveshaft slip-yoke. 1. Lubricate the stub shaft splines with approximately 10 grams
(0.24 oz) of lubricant, and pull the driveshaft slip-yoke boot towards the
driveshaft. ^
Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
2. Position the large driveshaft slip-yoke boot clamp. 3. Align the index marks made during
disassembly, and install the driveshaft slip-yoke.
5. Set the driveshaft assembled length to specification.
1. Remove any excess grease from the driveshaft slip-yoke surfaces. 2. Position the driveshaft
slip-yoke boot in the driveshaft slip-yoke boot groove. 3. Set the driveshaft assembled length to
specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Service and Repair > Page 6288
^ Measure from the driveshaft weld to the end of the driveshaft slip-yoke. Set the assembled length
to specification by moving the driveshaft slip-yoke inward or outward as necessary.
4. Bleed air from the driveshaft slip-yoke boot.
6. Using the special tool, crimp the large driveshaft slip-yoke boot clamp. 7. Install the driveshaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation
Universal Joint: Description and Operation
Universal Joints
The universal joints are: ^
lubed-for-life design and require no lubrication.
^ equipped with nylon thrust washers, located at each base of the bearing cup, which control end
play, position the needle bearing and improve grease movement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke
Universal Joint: Service and Repair Flange Yoke
Driveshaft Universal Joint-Flange Yoke
Special Tools
Special Tool(s)
Disassembly
1. Remove the driveshaft.
2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture.
Place the driveshaft on a suitable workbench, being careful not to damage the tube.
3. NOTE: If components are not marked and installed correctly, driveline imbalance can occur.
Index-mark the positions of the driveshaft components.
4. Clamp the U-Joint tool in a vise.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6294
5. Remove all four of the snap rings.
6. Remove the driveshaft flange yoke.
1. Position the driveshaft flange yoke in the U joint tool. 2. Press out a bearing cup. 3. Remove the
driveshaft flange yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the
driveshaft flange yoke.
7. Remove the spider.
1. Reposition the driveshaft in the U-Joint tool. 2. Press out the bearing cup. 3. Rotate the
driveshaft. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the spider.
8. Clean the yoke area at the end of the driveshaft.
Assembly
1. NOTE: Universal joint kits are to be installed as complete assemblies only. Do not mix
components from other U-Joint kits.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6295
Install the spider. 1. Start a new bearing cup into the driveshaft yoke.
^ Check the needle bearings for correct positioning.
2. Position the new spider in the driveshaft yoke. 3. Position the driveshaft in the U-Joint tool. 4.
Press the bearing cup to just below the snap ring groove.
^ Repeat for the other bearing cup.
2. Inspect the driveshaft flange yoke. Install new if necessary.
3. Install the driveshaft flange yoke.
1. Start a new bearing cup into the driveshaft flange yoke.
^ Check the needle bearings for correct positioning.
2. Position the driveshaft flange yoke. 3. Position the driveshaft in the U-Joint tool. 4. Press the
bearing cup to just below the snap ring groove.
^ Repeat for the other bearing cup.
4. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-Joint). If
difficulty is encountered with the yellow snap
rings, install the black snap rings.
Remove the driveshaft from the U-Joint tool, and install the four snap rings.
5. NOTE: Do not strike the bearings.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6296
Check the U-joints for freedom of movement. ^
If binding, strike the yoke with a brass or plastic hammer.
6. Install the driveshaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6297
Universal Joint: Service and Repair Slip Yoke
Driveshaft Universal Joint-Slip Yoke
Special Tools
Special Tool(s)
Disassembly
Initial disassembly 1. Remove the driveshaft.
2. CAUTION: Do not, under any circumstance, clamp the driveshaft assembly in the jaws of a vise
or similar holding fixture.Denting or localizing
fracture can result,causing driveshaft failure during vehicle operation.
Place the driveshaft on a suitable workbench. Do not to damage the tube.
3. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance can
occur.
Index-mark the driveshaft components.
4. Remove all four of the snap rings.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6298
5. Clamp the special tool in a vise.
Bearing cup removal
6. NOTE: If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the
way.
Remove the driveshaft slip-yoke. 1. Position the driveshaft slip-yoke in the special tool. 2. Press out
a bearing cup. 3. Rotate the driveshaft slip-yoke 180 degrees. 4. Press on the spider to remove the
remaining bearing cup. 5. Remove the driveshaft slip-yoke.
Final disassembly
7. Repeat Bearing cup removal in this procedure to remove the remaining bearing cups and the
spider from the driveshaft. 8. Clean the yoke area at each end of the driveshaft.
Assembly
Bearing cup installation
1. NOTE: Install the Universal Joint Kits as complete assemblies only. Do not mix components from
other Kits.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6299
Install the bearing cup. 1. Start a new bearing cup into the driveshaft yoke.
^ Check the needle bearings for correct positioning.
2. Position the new spider in the driveshaft yoke. 3. Using the special tool, press the bearing cup to
just below the snap ring groove.
2. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-Joint). If
difficulty is encountered with the yellow snap
rings, install the black snap rings.
Remove the driveshaft from the special tool, and install the snap ring. Opposite bearing cup
installation
3. Repeat Bearing cup installation in this procedure to install the bearing cup and the snap ring on
the opposite side of the driveshaft yoke.
Slip-yoke installation
4. Inspect the driveshaft slip-yoke. Install a new yoke, if necessary. 5. Repeat Bearing cup
installation in this procedure to install the driveshaft slip-yoke and the remaining new bearing cups
and snap rings.
Final assembly
6. NOTE: Do not strike the bearings.
Check the U-joints for freedom of movement. ^
If binding, strike the yoke with a brass or plastic hammer.
7. Install the driveshaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Flywheel Bolts Stage 1 10 ft. lbs.
Stage 2 52 ft. lbs.
Torque Converter-To-Flexplate Nuts 22-30 ft. lbs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
Flywheel Bolts in the sequence shown in two stages.
^ Stage 1: ............................................................................................................................................
........................................ 13 Nm (10 ft. lbs.).
^ Stage 2: ............................................................................................................................................
........................................ 71 Nm (52 ft. lbs.).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair >
Dowels - Flywheel
Flywheel: Service and Repair Dowels - Flywheel
Dowels, Flywheel
Removal and Installation
1. NOTE: Take care not to damage the flywheel dowel holes or the surface areas around the
flywheel dowel during removal.
Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open
hole and a pair of locking pliers where the flywheel dowel is installed in a blind hole.
2. NOTE: Care should be taken to drive the flywheel dowel squarely into place until it is fully seated
and to not damage the surrounding surface
areas.
Install all flywheel dowels by driving them into place using a brass or plastic mallet.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair >
Dowels - Flywheel > Page 6308
Flywheel: Service and Repair Flywheel - Removal and Installation
Flywheel
Removal
1. Remove the transmission.
2. Remove the flywheel. 3. Clean and inspect the flywheel.
Installation
1. NOTE: Special bolts are used for flywheel installation; do not use standard bolts.
Install the flywheel. ^
Tighten the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 13 Nm (10 ft. lbs.).
^ Stage 2: Tighten the bolts to 71 Nm (52 ft. lbs.).
2. Install the transmission.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T >
Component Information > Service and Repair
Bell Housing: Service and Repair
Dowels, Flywheel Housing to Block
Removal and Installation
1. NOTE: Take care not to damage the flywheel housing to block dowel holes or the surface areas
around the flywheel housing to block dowel hole
during removal.
Remove the flywheel housing to block dowels using a drift pin where the flywheel housing to block
dowel is installed in an open hole and a pair of locking pliers where the flywheel housing to block
dowel is installed in a blind hole.
2. NOTE: Care should be taken to drive the flywheel housing to block dowel squarely into place
until it is fully seated without damaging the
surrounding surface areas.
Install all flywheel housing to block dowels by driving them into place using a brass or plastic
mallet.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Specifications
Case: Specifications
Case Cover Bolts 12 - 16 ft.lb
Case Plug 30 - 43 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T >
Component Information > Specifications
Countershaft: Specifications
Counter Lever Shaft Bolt 6 - 8 ft.lb
Countershaft Locknut 94 - 144 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component
Information > Specifications
Drain Plug: Specifications
Drain plug 30 - 43 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Service and Repair
Extension Housing: Service and Repair
Extension Housing
Special Tools
Special Tools
Removal
1. Raise and support the vehicle.
2. Remove the drain plug and drain the transmission fluid.
3. NOTE: To maintain initial driveshaft balance, index-mark the driveshaft to the rear axle pinion
flange so it can be installed in its original
position.
Remove and support the rear driveshaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Service and Repair > Page 6330
4. Using the special tool, support the transmission.
^ Secure the transmission with a strap.
5. Remove the six crossmember bolts.
6. Remove the nuts.
7. Remove the (RH) transmission mount bolt.
1. Remove the bolt. 2. Reposition the exhaust mounting bracket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Service and Repair > Page 6331
8. Using the special tool, remove the extension housing seal.
9. Remove the extension housing.
Installation
1. Install the extension housing.
2. Using the special tool, install the extension housing seal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Service and Repair > Page 6332
3. Install the (RH) transmission mount bolt.
1. Position the exhaust bracket. 2. Install the bolt.
4. Position the crossmember and install the six bolts and nuts. 5. Remove High-Lift Transmission
Jack.
6. Install the nuts.
7. NOTE: To maintain initial driveshaft balance, align the index marks on the driveshaft and the
rear axle pinion flange made during removal.
Install the rear driveshaft.
8. Install the drain plug. 9. Refill the transmission with the specified amount of fluid.
^ Use MERCON(R) Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting
Ford specification MERCON(R).
10. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component
Information > Specifications
Fill Plug: Specifications
Fill Plug 30 - 43 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information
Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information
TSB 06-26-1
01/08/07
MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME
MANUAL TRANSMISSIONS
FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco
1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super
Duty 2001-2003 Explorer Sport Trac, Explorer Sport
LINCOLN: 2001-2002 Lincoln LS
MERCURY: 1984-1995 Cougar 1987-1999 Tracer
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the
service fluid for manual transmissions originally requiring MERCON(R).
ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can
now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual
usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic
Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue
until remaining inventory has been depleted.
SERVICE PROCEDURE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6340
Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper
fluid application on current and past model manual transmissions refer to the fluid usage chart.
(Figure 1)
WARNING
FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR
OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT
(XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS
RECOMMENDING THAT PARTICULAR FLUID.
USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6341
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications > Capacity Specifications
Fluid - M/T: Capacity Specifications
Manual Transmission
Capacity ...............................................................................................................................................
................................................................... 2.7 Quarts Note: Approximate refill. Service refill
capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a
level surface.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications > Capacity Specifications > Page 6344
Fluid - M/T: Fluid Type Specifications
Manual Transmission Fluid ..................................................................................................................
............................................................. Mercon ATF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T >
Component Information > Service and Repair
Flywheel Gear: Service and Repair
Ring Gear
Removal
WARNING: This procedure should be performed only by a properly equipped and experienced
acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety
goggles when handling the heated flywheel ring gear.
1. Remove the transmission. 2. Remove the clutch pressure plate and clutch disc. 3. Remove the
flywheel.
4. CAUTION:
^ Do not heat the flywheel ring gear beyond 278° C (500° F). Use heat indicating crayons to
prevent over heating.
^ Tap the flywheel ring gear evenly to prevent binding.
Remove the flywheel ring gear from the flywheel, ^
Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear off the
flywheel.
Installation
WARNING: This procedure should be performed only by a properly equipped and experienced
acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety
goggles when handling the heated flywheel ring gear.
1. CAUTION:
^ Do not heat the flywheel ring gear beyond 278° C (500° F). Use heat indicating crayons to
prevent over heating.
^ Keep the torch moving to prevent hot spots.
Evenly heat the flywheel ring gear.
2. Install the flywheel ring gear.
^ The bevel on the flywheel ring gear must face, the rear of the flywheel.
^ Use a brass drift.
3. Install the flywheel. 4. Install the clutch pressure plate and clutch disc. 5. Install the transmission.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6354
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6355
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 6358
Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6359
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6360
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6361
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Specifications
Shifter M/T: Specifications
Inner Gearshift Lever Boot Bolt 89 - 123 in.lb
Outer Gearshift Lever Boot Screws 45 - 79 in.lb
Gearshift Lever Bolt 20 - 29 ft.lb
Gear Selector Interlock Bolts 72 - 89 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Specifications > Page 6365
Shifter M/T: Service and Repair
Shift Lever and Boot
Removal and Installation
1. Raise the outer gearshift lever boot and console assembly to access the nut and eccentric stud
that retains the upper gearshift lever to the lower
gearshift lever. 1. Remove the two screws retaining the console to the floor. 2. Raise the outer
gearshift lever boot and console assembly to access the nut and eccentric stud.
2. Remove the nut.
3. Install the nut on the LH side of the lever, then tighten the nut to remove the eccentric stud out of
the gearshift lever.
4. Remove the upper gearshift lever and the outer gearshift lever boot and console assembly as an
assembly.
5. CAUTION: Note the position of the vehicle identification tags on the top of the inner gearshift
lever boot for correct installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Specifications > Page 6366
If necessary, remove the four screws and the inner gearshift lever boot.
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot,
M/T > Component Information > Service and Repair
Shift Boot: Service and Repair
"For information regarding this component please refer to Shift lever Service and Repair"
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Specifications
Transmission Mount: Specifications
Transmission Mount Bolts 64 - 81 ft.lb
Transmission Mount Nuts 64 - 81 ft.lb
Crossmember Bolts 39 - 53 ft.lb
Crossmember Nuts 39 - 53 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Locations > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6379
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6380
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 6383
Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Diagrams > Page 6384
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Diagrams > Page 6385
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Diagrams > Page 6386
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6392
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6393
Transmission Mode Switch: Service and Repair
Transmission Control Switch
Removal and Installation
1. Remove the Transmission Control Switch (TCS).
1. Remove the cover. 2. Remove the TCS.
2. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6397
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6398
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6399
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6400
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6401
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 6407
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 6408
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6411
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6412
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6413
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6414
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6415
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6416
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6417
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6418
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6419
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6420
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6421
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6422
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6423
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6424
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6425
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6426
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6427
Transmission Speed Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6428
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6429
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6430
Transmission Speed Sensor: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6431
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6432
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6433
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6434
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6440
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6441
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6442
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6443
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6444
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6445
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6446
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6447
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6448
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6449
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6450
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6451
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6452
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6453
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6454
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6455
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6456
Transmission Temperature Sensor/Switch: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6457
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6458
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6459
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6460
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed
Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 6467
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 6468
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed
Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed
Sensor > Page 6471
Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6472
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6473
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6474
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 6481
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 6482
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 6483
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6486
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6487
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6488
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6489
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6490
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6491
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6492
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6493
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6494
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6495
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6496
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6497
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 6498
Symbols
Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 6499
Symbols
Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 6500
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Information > Diagrams > Diagram Information and Instructions > Page 6501
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Information > Diagrams > Diagram Information and Instructions > Page 6502
Pressure Regulating Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6503
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6504
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6505
Diagram 29-4
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 6506
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module (PCM) varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift
strategy.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
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Information > Diagrams > Page 6507
Pressure Regulating Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Information > Diagrams > Page 6508
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
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Information > Diagrams > Page 6509
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Information > Diagrams > Page 6510
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications
Shift Interlock Solenoid: Specifications
Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications > Page 6514
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Removal and Installation
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag Supplemental Restraint System (SRS) components and
before servicing, replacing, adjusting or striking components near the front or side air bag sensors,
such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please
refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at
or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery
ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped).
Disconnect the battery ground cable. Wait at least one minute before proceeding with the
procedure to allow the backup power supply to deplete its energy.
2. Remove the lower steering column opening finish panel.
1. Remove the screws and position the hood release handle out of the way. 2. Remove the two
screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining
clips and remove the lower steering column opening finish panel.
3. Remove the five bolts and the lower steering column opening finish panel reinforcement.
4. Remove the four nuts and lower the steering column.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications > Page 6515
5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering
column.
6. Disconnect the electrical connector and remove the insert plate and shift lock actuator.
7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary
to install a new clip for installation.
Remove and discard the clip.
8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications
Shift Solenoid: Specifications
Solenoid Clamp Screws 53 - 71 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > Page 6519
Shift Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > Page 6520
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > Page 6521
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > Page 6522
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Diagram Information and Instructions > Page 6525
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Diagram Information and Instructions > Page 6526
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6527
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6528
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6529
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6530
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6531
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6532
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6533
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6534
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6535
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6536
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6537
Symbols
Symbols
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Diagram Information and Instructions > Page 6538
Symbols
Symbols
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Diagram Information and Instructions > Page 6539
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Diagram Information and Instructions > Page 6540
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Diagram Information and Instructions > Page 6541
Shift Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6542
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6543
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6544
Diagram 29-4
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 6545
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
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Page 6546
Shift Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Page 6547
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
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Page 6548
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
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Page 6549
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
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Information > Locations
Torque Converter Clutch Solenoid: Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Information > Locations > Page 6553
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Information > Locations > Page 6554
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Information > Locations > Page 6555
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Information > Diagrams > Diagram Information and Instructions > Page 6558
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Information > Diagrams > Diagram Information and Instructions > Page 6559
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Information > Diagrams > Diagram Information and Instructions > Page 6561
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Information > Diagrams > Diagram Information and Instructions > Page 6562
Circuit Identification Chart
System Codes Chart
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Information > Diagrams > Diagram Information and Instructions > Page 6563
Sample Diagrams
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6564
Sample Diagram
Sample Diagram
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Information > Diagrams > Diagram Information and Instructions > Page 6565
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Information > Diagrams > Diagram Information and Instructions > Page 6566
Circuit Identification Chart
SYSTEM CODES CHART
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Information > Diagrams > Diagram Information and Instructions > Page 6567
SAMPLE DIAGRAMS
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Information > Diagrams > Diagram Information and Instructions > Page 6568
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6569
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6570
Symbols
Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 6571
Symbols
Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 6572
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Information > Diagrams > Diagram Information and Instructions > Page 6573
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Information > Diagrams > Diagram Information and Instructions > Page 6574
Torque Converter Clutch Solenoid: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6575
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6576
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6577
Diagram 29-4
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Information > Diagrams > Page 6578
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
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Information > Diagrams > Page 6579
Torque Converter Clutch Solenoid: Service and Repair
Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan
rail and positioned out of the way for fluid pan
removal.
If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. NOTE: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. ^
Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Information > Diagrams > Page 6580
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch
(TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid
electrical connector.
9. CAUTION:
^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the
solenoid or converter modulator valve.
^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
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Information > Diagrams > Page 6581
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque
Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. ^
Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
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Information > Diagrams > Page 6582
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R)
V specification.
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Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
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Diagrams
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Diagrams > Page 6593
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
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Diagrams > Page 6594
Transmission Mode Switch: Service and Repair
Transmission Control Switch
Removal and Installation
1. Remove the Transmission Control Switch (TCS).
1. Remove the cover. 2. Remove the TCS.
2. To install, reverse the removal procedure.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb
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Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6598
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Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6599
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Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6600
Digital Transmission Range Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
Removal
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital Transmission Range (TR) sensor electrical connector.
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Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6601
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6602
4. Connect the digital Transmission Range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle.
8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its
adaptive strategy. The customer needs to be notified that they may experience slightly different
upshifts either soft or firm and this is a temporary condition and will eventually return to normal
operating condition.
Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 6608
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 6609
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6612
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6613
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6614
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6615
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6616
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6617
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6618
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6619
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6620
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6621
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6622
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6623
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6624
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6625
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6626
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6627
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6628
Transmission Speed Sensor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6629
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6630
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6631
Transmission Speed Sensor: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 6632
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 6633
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 6634
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
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Diagrams > Page 6635
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6641
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6642
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6643
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6644
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6645
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6646
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6647
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6648
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6649
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6650
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6651
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6652
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6653
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6654
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6655
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6656
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6657
Transmission Temperature Sensor/Switch: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6658
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6659
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6660
Diagram 29-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Page 6661
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Locations > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 6668
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 6669
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Intermediate Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Intermediate Shaft Speed Sensor > Page 6672
Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Page 6673
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Page 6674
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Page 6675
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations > Page 6681
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed
Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed
Sensor > Component Information > Locations > Page 6685
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control
Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set
Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON DTCB2607 May Be
Set
Article No. 01-6-1
04/02/01
^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
FORD: 2001 EXPLORER
ISSUE
The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607
may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp
may remain on or may illuminate intermittently. This may be due to the ABS module remaining
active when the engine is cranked and both blower motors are on.
ACTION
Replace the ABS module with an updated module if existing module is the original design, and
check for proper circuit grounding. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
It the ABS lamp is on intermittently:
1. Replace the ABS module.
a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Test drive vehicle to verify repair.
If the ABS lamp is on continuously:
1. Replace the ABS module.
a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 3.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control
Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6694
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
3. Verify if the vehicle is a 4X4 or 4X2.
^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded.
^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary.
4. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 5.
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 301000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set
Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON
DTCB2607 May Be Set
Article No. 01-6-1
04/02/01
^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
FORD: 2001 EXPLORER
ISSUE
The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607
may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp
may remain on or may illuminate intermittently. This may be due to the ABS module remaining
active when the engine is cranked and both blower motors are on.
ACTION
Replace the ABS module with an updated module if existing module is the original design, and
check for proper circuit grounding. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
It the ABS lamp is on intermittently:
1. Replace the ABS module.
a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Test drive vehicle to verify repair.
If the ABS lamp is on continuously:
1. Replace the ABS module.
a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 3.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6700
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
3. Verify if the vehicle is a 4X4 or 4X2.
^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded.
^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary.
4. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 5.
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 301000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 6701
Electronic Brake Control Module: Specifications
Control module bolts 13 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 6702
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 6703
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 6704
Electronic Brake Control Module: Description and Operation
Anti-Lock Brake Control Module
NOTE: The new anti-lock brake control module must be reconfigured upon installation.
The anti-lock brake control module is mounted to the HCU. It is an on-board diagnostic,
non-repairable unit consisting of two microprocessors and the necessary circuitry for their
operation. The anti-lock brake control module monitors system operation during normal driving as
well as during anti-lock braking. Anti-lock brake module operation is as follows: ^
Under normal driving conditions, the microprocessor produces short test pulses to the solenoid
valves that check the electrical system without any mechanical reaction.
^ Impending wheel lock conditions trigger signals from the anti-lock brake control module that open
and close the appropriate solenoid valves. This results in moderate pulsations in the brake pedal.
During normal braking, the brake pedal feel will be identical to a standard brake system. Most faults
that occur in the anti-lock brake system will be stored as a diagnostic trouble code (DTC) in the
keep-alive memory of the anti-lock brake control module. The DTCs can be retrieved by following
the on-board diagnostic procedures.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 6705
Electronic Brake Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 6706
Electronic Brake Control Module: Service and Repair
Module-Anti-Lock Brake Control
Removal and Installation
1. Disconnect the battery ground cable.
2. Disconnect the electrical connectors.
3. Remove the anti-lock brake control module.
1 Remove the bolts.
2 Remove the anti-lock brake control module.
4. CAUTION: Once the new module is installed, the module configuration information may have to
be entered.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Hydraulic control unit (HCU) to bracket bolts 71 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 6710
Hydraulic Control Assembly - Antilock Brakes: Description and Operation
Hydraulic Control Unit
The HCU consists of the following components: ^
brake pressure control valve block
^ pump motor
New brake pressure control valve block and pump motor are installed as an assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 6711
Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 6712
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit
Removal and Installation
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector by lifting up on the release tab.
3. Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU.
1 Remove the bolts.
2 Remove the HCU.
5. If necessary, remove the anti-lock brake control module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 6713
6. CAUTION: After the electronic hydraulic control unit is installed, it is necessary to bleed the
hydraulic brake system.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > Front
Wheel Speed Sensor: Specifications
Front anti-lock brake sensor bolt (4x2) 8.5 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > Front > Page 6718
Wheel Speed Sensor: Specifications
Rear anti-lock brake sensor bolt 20 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Left front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Left front > Page 6721
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 6724
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 6725
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Page 6726
Wheel Speed Sensor: Description and Operation
Anti-Lock Brake Sensor
NOTE: Any time an anti-lock brake sensor is removed, thoroughly clean the mounting surfaces. On
front anti-lock brake sensors, apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease
E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.
The anti-lock brake system uses three variable-reluctance sensors to determine vehicle speed. The
anti-lock brake sensors operate on magnetic induction principle. As the teeth on the anti-lock brake
sensor indicator rotate past the stationary sensor, a signal proportional to the speed of the rotation
is generated and sent to the anti-lock brake control module through a twisted cable and shielded
wiring harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Rear Antilock Control
Wheel Speed Sensor: Service and Repair Rear Antilock Control
Sensor-Rear
Removal and Installation
1. Raise and support vehicle.
2. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake
sensor before removal.
Remove the rear anti-lock brake sensor. 1
Disconnect the rear anti-lock brake sensor electrical connector.
2 Remove the bolt.
3 Remove the rear anti-lock brake sensor.
3. NOTE: Thoroughly clean the mounting surface.
NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE
75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford
specification WSL-M2C192-A.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 6729
Wheel Speed Sensor: Service and Repair Sensor, Front
Sensor-Front 4x2
Removal and Installation
1. Raise and support the vehicle.
2. Disconnect the front anti-lock brake sensor wire from the vehicle frame.
1 Disconnect the electrical connector.
2 Unclip the front anti-lock brake sensor wire from the vehicle frame.
3. Remove the front anti-lock brake sensor.
1 Remove the bolt.
2 Remove the front anti-lock brake sensor.
4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply
High-Temperature 4x4 Front Axle and Wheel Bearing
Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 6730
Wheel Speed Sensor: Service and Repair Sensor, Rear
Sensor-Rear
Removal and Installation
NOTE: The rear anti-lock brake sensor indicator is attached to the differential case.
For additional information, refer to Transmission and Drivetrain; Differential.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications
Brake Bleeding: Specifications
Disc brake caliper bleeder screw 15 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding
Brake Bleeding: Service and Repair Brake Caliper Bleeding
Caliper
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6736
Brake Bleeding: Service and Repair Brake System Manual Bleeding
Manual
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Disc brake is shown, drum brake is similar.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the tube in a container partially filled with clean brake
fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6737
4. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw, ending with the LH front bleeder
screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6738
Brake Bleeding: Service and Repair Brake System Pressure Bleeding
Pressure
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Disc brake is shown, drum brake is similar.
NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6739
5. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front bleeder screw, ending with the LH front
bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6740
Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU)
Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU)
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
NOTE: This procedure only needs to be carried out if a new 4-wheel anti-lock brake (4WABS)
hydraulic control unit (HCU) has been installed.
1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash, and follow the scan tool instructions for
bleeding.
2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
3. NOTE: Disc brake is shown, drum brake is similar.
Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially
filled with recommended brake fluid.
4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6741
5. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw, ending with the LH front bleeder
screw.
7. Repeat the bleed procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6742
Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench
Master Cylinder Priming-In-Vehicle or Bench
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake component and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air
can get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When a new brake master cylinder has been installed or the system has been emptied or
partially emptied, it must be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder.
2. For bench priming, mount the brake master cylinder in a vise.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6743
3. Install short brake tubes with the ends bent into the brake master cylinder reservoir.
^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.
4. For a new brake master cylinder, loosen the speed control pressure switch. 5. Slowly depress
and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the
brake pedal.
6. Tighten the speed control pressure switch. 7. Repeat the above three steps until no air bubbles
are visible in the expelled fluid. 8. Slowly depress the primary piston or, for in-vehicle priming, have
an assistant slowly pump the brake pedal until clear brake fluid flows from both
brake tubes with no air bubbles.
9. If necessary, install the brake master cylinder into the vehicle.
10. Remove the short brake tubes and install the master cylinder outlet tubes.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6744
11. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU).
12. NOTE: Refill the brake master cylinder reservoir as necessary.
Have an assistant depress and hold the brake pedal.
13. Tighten the outlet tube fitting at the HCU. 14. Repeat the above three steps until no air bubbles
are visible in the expelled brake fluid.
15. Repeat the above four steps for the remaining master cylinder outlet tube.
16. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other
end in a container partially filled with the specified
brake fluid.
17. Have an assistant pump and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 6745
18. NOTE: Refill the brake master cylinder reservoir as necessary.
Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube.
19. Tighten the master cylinder bleeder screw. 20. Repeat the above three steps until there are no
air bubbles in the expelled brake fluid. 21. Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Page 6746
Brake Bleeding: Tools and Equipment
Special Tools
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications
Brake Pedal Assy: Specifications
Brake pedal bracket bolts and nuts 18 ft.lb
Brake pedal bracket nuts 18 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 6750
Brake Pedal Assy: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Brakes and Traction Control; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 6751
Brake Pedal Assy: Service and Repair
Brake Pedal and Bracket
Removal and Installation
All vehicles
1. NOTE: When removing the stoplight switch, retain the bushing and hairpin clip. They will be
required for installation.
Disconnect the brake booster push rod. 1
Remove the hairpin clip.
2 Separate the stoplight switch and the brake booster push rod from the brake pedal pin.
3 Remove the brake booster push rod bushing.
Vehicles with manual transmission
2. Disconnect the clutch master cylinder push rod.
3. Disconnect the clutch pedal position switch (CPP).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 6752
4. Remove the clutch master cylinder by rotating the clutch master cylinder 45 degrees clockwise.
5. Remove the bulkhead sound insulator.
All vehicles
6. Remove the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 6753
7. CAUTION: Support the brake master cylinder and power brake booster in the engine
compartment.
Remove the nuts and the brake pedal assembly.
8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications
Brake Caliper: Specifications
Caliper bleeder screw, rear 15 in.lb
Caliper bleeder screw, front 15 in.lb
Front disc brake caliper anchor plate bolts 72-97 ft.lb
Disc brake caliper bolts 21-26 ft.lb
Brake caliper bolts 20 ft.lb
Caliper flow bolt 23-29 ft.lb
Rear wheel disc brake adapter bolts 80 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front
Brake Caliper: Service and Repair Front
Caliper Removal and Installation
Caliper
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly.
3. WARNING: Use of any other than approved DOT 3 brake fluid will cause damage to brake
components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not clamp the brake hose. The hose can be damaged.
Disconnect the front brake hose. 1
Remove the front brake hose bolt.
2 Disconnect the front brake hose.
3 Remove and discard the copper washers. Plug the front brake hose.
4. Remove the disc brake caliper.
1 Remove the disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6760
5. Inspect the disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. Install the disc brake caliper.
1 Install the disc brake caliper.
2 Install the disc brake caliper bolts.
2. Install the front brake hose.
^ Use new copper washers; connect the front brake hose.
^ Install the front brake hose bolt.
3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Check the brake system
for correct operation.
Caliper Disassembly and Assembly
Caliper
Disassembly
WARNING: Use of any brake fluid other than approved DOT 3 will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6761
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB
or equivalent meeting Ford specification ESA-M6C25A. ^
Do not reuse brake fluid drained or bled from the system.
^ Do not use brake fluid that has been stored in an open container.
^ Do not use contaminated brake fluid.
1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3.
Secure the disc brake caliper in a vise.
4. Remove the caliper pistons.
1 Place a block of wood between the caliper bridge and the caliper pistons.
2 Apply low air pressure to the fluid port in the disc brake caliper.
3 Force out the caliper piston to the block of wood.
4 Remove the block of wood and the caliper pistons.
5. Remove and discard the piston seals and boots.
6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.
If the caliper bores are excessively scored or corroded, install a new disc brake caliper.
Assembly
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6762
1. CAUTION: Never reuse piston seals or dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance
DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification
ESA-M6C25-A.
2. Install the caliper pistons.
1 Install the piston seal.
2 Install the piston boot.
3 CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston.
3. Install the disc brake caliper.
Brake Caliper Anchor Plate
Brake Caliper Anchor Plate
Removal
1. NOTE: 4x4 is shown, 4x2 is similar.
Remove the pads.
2. Remove the front disc brake caliper anchor plate.
1 Remove the two front disc brake caliper anchor plate bolts.
2 Remove the front disc brake caliper anchor plate.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6763
1. Install the front disc brake caliper anchor plate.
1 Position the front disc brake caliper anchor plate.
2 Install the front disc brake caliper anchor plate bolts.
2. Install the pads.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6764
Brake Caliper: Service and Repair Rear
Caliper Removal and Installation
Caliper
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly.
3. WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes
inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not clamp the brake hose. The hose can be damaged.
Disconnect the brake hose. 1
Remove the bolt.
2 Disconnect the rear wheel brake hose.
3 Remove the copper washers and plug the brake hose.
4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are
not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A
(Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-MlC171-A
for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in
contamination and accelerated corrosion or wear of the caliper slide pin mechanism.
Remove the rear disc brake caliper. 1
Remove the brake caliper bolts.
2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6765
5. Inspect the rear disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct
caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the
rear disc brake caliper.
Install the rear disc brake caliper.
2. Install the rear wheel brake hose.
^ Connect the brake hose and install the caliper flow bolt. Use new copper washers.
3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Verify correct brake
operation.
Caliper Disassembly and Assembly
Caliper
Disassembly
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6766
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake
caliper. 3. Secure the rear disc brake caliper in a vise.
4. Remove the rear disc brake piston.
1 Place a block of wood between the caliper bridge and the rear disc brake piston.
2 Apply low air pressure to the fluid port in the rear disc brake caliper.
3 Force the rear disc brake piston out to the block of wood.
4 Remove the block of wood and the rear disc brake piston.
5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the
rear disc brake caliper cylinder bore/piston is
excessively scored or corroded, install a new rear disc brake caliper.
Remove and discard the piston seal and dust boot.
Assembly
CAUTION: Never reuse the piston seal or dust boot.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6767
1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford
specification ESA-M6C25-A. ^
cylinder bore
^ piston seal
^ rear disc brake piston
^ dust boot
2. Install the piston seal.
3. Install the dust boot.
4. CAUTION: Be careful not to damage or dislodge the piston seal.
Install the rear disc brake piston.
5. Install the rear disc brake caliper.
Rear Disc Brake Adapter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6768
Adapter
Removal and Installation
1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft.
3. Remove the bolts and the rear wheel disc brake adapter. 4. To install, reverse the removal
procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Page 6769
Brake Caliper: Tools and Equipment
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications
Brake Pad: Specifications
Minimum thickness above the metal backing plate or rivets 0.10 in
Brake hose bolt 23-29 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front
Brake Pad: Service and Repair Front
Pads
Removal
1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. Raise and
support the vehicle. 3. Remove the wheel and tire assembly.
4. CAUTION: Install a new pad if worn to or past the specified thickness above the metal backing
plate or rivets. Install new pads in complete axle
sets.
Inspect the pads for wear or contamination.
5. Remove the lower caliper bolt.
6. Rotate the disc brake caliper upward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6775
7. Remove the pads and the slippers.
1 Remove the pads.
2 Remove the stainless slippers.
8. NOTE: 4x2 is shown, 4x4 is similar.
Inspect the brake disc. ^
If the brake disc is cracked, install a new brake disc.
^ If diagnosis has revealed vibration in the steering wheel, seat, or brake pedal while braking,
machine the brake disc. Heavily scored brake discs, similar to that caused by linings worn to the
backing plate, must also be machined.
^ Measure the brake disc for minimum thickness.
^ If the brake disc is not within specification, install a new brake disc.
9. Inspect the disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6776
1. NOTE: Use a suitable suction device to remove brake fluid from the master cylinder.
NOTE: Clean the anchor plate and slipper surfaces.
Install the slippers and the pads. 1
Install the slippers.
2 Install the pads.
2. NOTE: If installing new pads, the caliper pistons must be compressed using a C-clamp and a
wooden block. Lower the brake fluid level in the
master cylinder if required.
Rotate the disc brake caliper downward.
3. Install the caliper bolt. 4. Install the wheel and tire assembly. 5. Check the brake system for
correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6777
Brake Pad: Service and Repair Rear
Pads
Removal
1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full.
2. CAUTION: Install new pads if worn to or past the specified thickness above the metal backing
plate or rivets. Install new pads in complete axle
sets.
Inspect the brake pads for wear or contamination. Install new pads if worn to or past specification.
3. NOTE: It is not necessary to remove the rear wheel brake hose when carrying out this
procedure.
Remove the rear disc brake caliper.
4. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads.
Remove the brake pads.
5. Retract the caliper piston into the rear disc brake caliper.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6778
6. Remove and discard the slippers.
7. Inspect the brake disc.
^ If the brake disc is cracked, install a new brake disc.
^ If diagnosis has revealed vibration in the steering wheel, seat, or brake pedal while braking,
machine the brake disc. Heavily scored brake discs, similar to that caused by linings worn to the
backing plate, must also be machined.
^ Measure the brake disc for minimum thickness.
^ If the brake disc is not within specification, install a new brake disc.
Installation
1. CAUTION: New stainless steel slippers must be installed when new brake pads are installed,
even if the slippers appear undamaged. Make sure
the slippers are correctly positioned with the slipper ends snug against the outboard end of the
anchor plate rail.
Clean the slipper mating surface, and install the new slippers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6779
2. CAUTION: Install new brake pads in full axle sets. Do not install new brake pads on only one
side of the vehicle.
Install the brake pads.
3. Install the rear disc brake caliper. 4. Verify correct brake operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Brake Rotor/Disc
Brake Rotor/Disc: Specifications Brake Rotor/Disc
..............................................................................................................................................................
........................................................ Min Thickness
Front ....................................................................................................................................................
............................................. 0.9646 inch (24.50mm)
Rear .....................................................................................................................................................
..................................................
0.4331 inch (11mm)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Brake Rotor/Disc > Page 6784
Brake Rotor/Disc: Specifications
Brake disc shield bolts 7-10 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front
Brake Rotor/Disc: Service and Repair Front
Brake Disc
Disc
Removal
All vehicles 1. Remove the front disc brake caliper anchor plate.
4x4 vehicles
2. NOTE: Match-mark the brake disc and hub. Remove the brake disc.
3. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc. Measure the
brake disc and resurface as necessary.
Install a new brake disc if beyond specification.
4x2 vehicles
4. NOTE: Match-mark the brake disc and hub.
Remove the brake disc and hub as follows: 1
Remove the hub grease cap.
2 Remove the cotter pin.
3 Remove the nut retainer.
4 Remove the spindle nut.
5 Remove the front wheel outer bearing retainer washer.
6 Remove the outer front wheel bearing.
7 Remove the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6787
5. Remove the wheel hub grease seal and wheel bearing.
1 Remove the wheel hub grease seal.
2 Remove the wheel bearing.
6. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc.
Measure the brake disc, and resurface as necessary. Install a new brake disc if beyond
specification.
Installation
4x4 vehicles 1. Position the brake disc to the wheel hub.
^ Use Metal Brake Parts Cleaner F6AZ-2C410-AB or equivalent to clean the brake disc.
^ Using match-marks, mount the brake disc on the hub.
^ Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford
specification ESE-M12A4-A to the hub mounting surface to prevent future corrosion.
4x2 vehicles
2. Thoroughly clean and inspect the front wheel bearings and the brake disc and hub.
^ Use Metal Brake Parts Cleaner F6AZ-2C410-AB or equivalent.
3. Lubricate the front wheel bearings.
^ Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification
ESA-M1C75-B.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6788
4. Install a new wheel hub grease seal.
1 Install the inner front wheel bearing.
2 Install a new wheel hub grease seal.
5. Install the brake disc and hub.
1 Position the brake disc and hub.
2 Install the outer front wheel bearing.
3 Install the front wheel outer bearing retainer washer.
4 Install the spindle nut.
6. Tighten the spindle nut while rotating the brake disc and hub.
7. Loosen the spindle nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6789
8. Tighten the spindle nut while rotating the brake disc and hub.
9. Install the following components:
1 Install the nut retainer.
2 Install the cotter pin.
3 Install the hub grease cap.
All vehicles 10. Install the front disc brake caliper anchor plate.
Brake Disc Shield
Shield-4x2
Removal and Installation
1. Remove the brake disc.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6790
2. Remove the bolts and the brake disc shield. 3. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6791
Brake Rotor/Disc: Service and Repair Rear
Brake Disc
Disc
Removal and Installation
1. NOTE: When removing the rear brake disc in this procedure it is not necessary to disconnect the
hydraulic lines.
Remove the rear disc brake caliper.
2. NOTE: If the rear brake disc binds on the rear parking brake shoe and linings, remove the
adjustment hole access plug and retract the parking
brake shoe and lining.
Remove the rear brake disc.
3. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc.
Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond
specification.
4. To install, reverse the removal procedure.
Brake Disc Shield
Shield
Removal
1. Remove the rear wheel disc brake adapter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6792
2. Remove the rear wheel disc brake shield.
1 Drill out the rivet, (if present).
2 Remove the rear wheel disc brake shield.
Installation
1. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc
brake adapter bolts, a new rivet is not required.
Seal the rivet hole with Clear Silicone Rubber F7AZ-19554-CA or equivalent meeting Ford
specification ESB-M4G92-A, and install the rear wheel disc brake shield.
2. Install the rear wheel disc brake adapter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information >
Specifications
Backing Plate: Specifications
Brake backing plate nuts 40-50 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information >
Specifications > Page 6797
Backing Plate: Service and Repair
Backing Plate
Removal and Installation
1. Remove the rear brake shoes and linings.
2. Pull back the parking brake cable spring and disconnect the parking brake lever. 3. Remove the
axle shaft or the axle shaft and rear hub, if so equipped.
4. Compress the cable retainer and pull the parking brake rear cable and conduit from the brake
backing plate.
5. Remove the rear wheel cylinder.
1 Disconnect the brake line fitting.
2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder.
6. Remove the four backing plate-to-axle flange nuts and bolts and the brake backing plate. 7. To
install, reverse the removal procedure. 8. Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications
Brake Drum: Specifications
..............................................................................................................................................................
.............................................. Max Drum Diameter
Rear .....................................................................................................................................................
......................................... 11.0866 inch (281.60mm)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications > Page 6801
Brake Drum: Service and Repair
Drum
Removal and Installation
WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous
to health if inhaled.
Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with
asbestos fibers, such as a Brake/Clutch/Service Vacuum. The bag must be labeled per OSHA
instructions, sealed, and the trash hauler notified as to the bag's contents.
WARNING: If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust
generation is still possible, technicians must wear government-approved toxic dust purifying
respirators.
The occupational safety and health act (OSHA) requires areas where asbestos dust generation is
possible to be isolated and posted with warning signs. Only technicians performing brake or clutch
repair are to be present in the area.
WARNING: To reduce the possibility of uneven braking, always install new rear brake shoes and
linings at both ends of an axle.
NOTE: Make sure that the parking brake control is fully released.
1. Remove the wheel and tire assembly.
2. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can
result.
NOTE: If the brake drum is rusted to the axle shaft pilot diameter, tap the center of the brake drum
between the wheel studs.
Remove the brake drum. 1
Remove and discard the spring nut.
2 Pull the brake drum off the axle shaft.
3. NOTE: If the brake drum will not come off, follow these steps.
Loosen the brake shoe adjusting screw nut. 1
Using a screwdriver, move the brake shoe adjusting lever off the brake adjuster screw.
2 NOTE: Move the adjustment tool handle downward to loosen the brake shoe adjusting screw nut.
Use the Brake Adjustment Tool to loosen the brake shoe adjusting screw nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications > Page 6802
4. Using the Brake Drum Micrometer, measure the brake drum inside diameter.
^ Install a new brake drum if the maximum inside diameter exceeds the specification molded on the
brake drum.
5. NOTE: If adjusting the rear brakes.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications > Page 6803
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications
Brake Shoe: Specifications
Lining minimum thickness 0.03 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications > Page 6807
Brake Shoe: Adjustments
Brake Drums Removed
WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous
to health if inhaled.
Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with
asbestos fibers, such as a Brake/Clutch/Service Vacuum. The bag must be labeled per OSHA
instructions, sealed, and the trash hauler notified as to the bag's contents.
If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is
still possible, technicians must wear government-approved toxic dust purifying respirators.
The occupational safety and health act (OSHA) requires areas where asbestos dust generation is
possible to be isolated and posted with warning signs. Only technicians performing brake or clutch
repair are to be present in the area.
NOTE: After adjusting the rear brake shoes and linings, check the parking brake for correct
operation. Make sure the parking brake cable equalizer operates freely.
1. Measure the brake drum inside diameter.
^ Use a brake adjustment gauge.
2. Adjust the rear brake shoes and linings.
^ Rotate the brake adjuster screw until the rear brake shoes and linings touch the tool.
Brake Drums Installed
1. Raise and support the vehicle. 2. At the back of the brake backing plate, remove the brake
adjusting hole cover.
3. Rotate the brake shoe adjusting screw nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications > Page 6808
1 Using a screwdriver, move the brake shoe adjusting lever off the brake shoe adjusting screw nut.
2 NOTE: Move the adjustment tool handle upward to tighten the brake adjuster screw.
Turn the brake shoe adjusting screw nut until the brake drum begins to drag. Then loosen the
brake adjuster screw until the brake drum rotates freely.
4. Install a new brake adjusting hole cover. 5. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications > Page 6809
Brake Shoe: Service and Repair
Shoes
Removal
1. Remove the brake drum.
2. Inspect the rear brake assembly for the following:
^ the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and
rebuild as necessary.
^ the rear brake shoes and linings for contamination, and install new shoes and linings as
necessary.
^ the rear brake shoes and linings for minimum thickness, above the backing plate or rivets, and
install new as necessary.
^ the springs for heat discoloration, and install new as necessary.
^ the adjusting lever contact with the brake adjuster screw.
3. NOTE: To aid installation, note the locations of the short and long brake shoe retracting springs.
Remove the brake shoe retracting springs. 1
Remove the long brake shoe retracting spring.
2 Remove the short brake shoe retracting spring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications > Page 6810
4. Remove the adjusting screw assembly.
1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever.
2 Remove the brake shoe adjusting lever cable.
3 Remove the cable guide.
4 Remove the adjusting lever return spring and the brake shoe adjusting lever.
5 Remove the brake shoe adjusting screw spring.
6 Remove the brake adjuster screw assembly.
5. NOTE: The parking brake link spring and the brake parking spring retainer will come off with the
parking brake strut.
Remove the brake shoe anchor pin guide plate, parking brake strut and the parking brake lever pin
retainer.
6. Remove the rear brake shoes and linings.
1 Remove the brake shoe hold-down springs.
2 Remove the rear brake shoes and linings.
3 Remove the brake shoe hold-down spring pins.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications > Page 6811
1. Clean and lubricate the brake backing plate.
^ Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft
WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A.
2. Attach the parking brake lever to the rear brake shoe and lining and secure the parking brake
lever pin retainer.
3. Install the rear brake shoes and linings.
1 Position the rear brake shoes and linings.
2 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs.
4. Install the parking brake strut.
1 Install the parking brake link spring and the parking brake spring retainer on the parking brake
strut.
2 Install the parking brake strut.
3 Install the brake shoe anchor pin guide plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications > Page 6812
5. Install the short brake shoe retracting spring.
1 Place the brake shoe adjusting lever cable over the anchor pin, with crimped side in.
2 Install the short brake shoe retracting spring.
6. NOTE: Make sure the brake shoe adjusting lever cable is positioned in the cable guide groove.
Install the long brake shoe retracting spring. 1
Install the cable guide.
2 Position the brake shoe adjusting lever cable in the cable guide groove.
3 Install the long brake shoe retracting spring.
7. Disassemble the brake adjuster screw assembly and apply Silicone Brake Caliper Grease and
Dielectric Compound D7AZ-19A331-A (Motorcraft
WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A.
8. Assemble the brake adjuster screw assembly.
9. NOTE: To prevent incorrect installation, the socket end of each brake adjuster screw is stamped
R or L.
Install the brake adjuster screw assembly. 1
Position the brake adjuster screw assembly.
2 Install the brake shoe adjusting screw spring.
3 Position the brake shoe adjusting lever cable.
4 Position the adjusting lever return spring and the brake shoe adjusting lever.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications > Page 6813
5 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever.
10. Test the operation of the automatic self-adjuster.
1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates
the brake shoe adjuster assembly.
2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever
advances to the next notch on the brake shoe adjusting screw nut.
11. Adjust the brakes. 12. Install the brake drum.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Specifications > Page 6814
Brake Shoe: Tools and Equipment
Special Tools
Special Tools
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Specifications
Wheel Cylinder: Specifications
Rear wheel cylinder bleeder screw 15 ft.lb
Rear wheel cylinder bolts 11 ft.lb
Brake line-to-rear wheel cylinder fitting 13 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Specifications > Page 6818
Wheel Cylinder: Service and Repair
Wheel Cylinder
Removal and Installation
1. Remove the brake shoes and linings.
2. Remove the rear wheel cylinder.
1 Disconnect the brake line fitting.
2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder.
3. To install, reverse the removal procedure. 4. Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Specifications
Brake Bleeding: Specifications
Disc brake caliper bleeder screw 15 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding
Brake Bleeding: Service and Repair Brake Caliper Bleeding
Caliper
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6825
Brake Bleeding: Service and Repair Brake System Manual Bleeding
Manual
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Disc brake is shown, drum brake is similar.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the tube in a container partially filled with clean brake
fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6826
4. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw, ending with the LH front bleeder
screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6827
Brake Bleeding: Service and Repair Brake System Pressure Bleeding
Pressure
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Disc brake is shown, drum brake is similar.
NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6828
5. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front bleeder screw, ending with the LH front
bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6829
Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU)
Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU)
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
NOTE: This procedure only needs to be carried out if a new 4-wheel anti-lock brake (4WABS)
hydraulic control unit (HCU) has been installed.
1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash, and follow the scan tool instructions for
bleeding.
2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
3. NOTE: Disc brake is shown, drum brake is similar.
Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially
filled with recommended brake fluid.
4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6830
5. NOTE: Disc brake is shown, drum brake is similar.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front
bleeder screw, ending with the LH front bleeder
screw.
7. Repeat the bleed procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6831
Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench
Master Cylinder Priming-In-Vehicle or Bench
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake component and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air
can get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When a new brake master cylinder has been installed or the system has been emptied or
partially emptied, it must be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder.
2. For bench priming, mount the brake master cylinder in a vise.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6832
3. Install short brake tubes with the ends bent into the brake master cylinder reservoir.
^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.
4. For a new brake master cylinder, loosen the speed control pressure switch. 5. Slowly depress
and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the
brake pedal.
6. Tighten the speed control pressure switch. 7. Repeat the above three steps until no air bubbles
are visible in the expelled fluid. 8. Slowly depress the primary piston or, for in-vehicle priming, have
an assistant slowly pump the brake pedal until clear brake fluid flows from both
brake tubes with no air bubbles.
9. If necessary, install the brake master cylinder into the vehicle.
10. Remove the short brake tubes and install the master cylinder outlet tubes.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6833
11. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU).
12. NOTE: Refill the brake master cylinder reservoir as necessary.
Have an assistant depress and hold the brake pedal.
13. Tighten the outlet tube fitting at the HCU. 14. Repeat the above three steps until no air bubbles
are visible in the expelled brake fluid.
15. Repeat the above four steps for the remaining master cylinder outlet tube.
16. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other
end in a container partially filled with the specified
brake fluid.
17. Have an assistant pump and then hold firm pressure on the brake pedal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 6834
18. NOTE: Refill the brake master cylinder reservoir as necessary.
Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube.
19. Tighten the master cylinder bleeder screw. 20. Repeat the above three steps until there are no
air bubbles in the expelled brake fluid. 21. Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Page 6835
Brake Bleeding: Tools and Equipment
Special Tools
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications
Brake Caliper: Specifications
Caliper bleeder screw, rear 15 in.lb
Caliper bleeder screw, front 15 in.lb
Front disc brake caliper anchor plate bolts 72-97 ft.lb
Disc brake caliper bolts 21-26 ft.lb
Brake caliper bolts 20 ft.lb
Caliper flow bolt 23-29 ft.lb
Rear wheel disc brake adapter bolts 80 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front
Brake Caliper: Service and Repair Front
Caliper Removal and Installation
Caliper
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly.
3. WARNING: Use of any other than approved DOT 3 brake fluid will cause damage to brake
components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not clamp the brake hose. The hose can be damaged.
Disconnect the front brake hose. 1
Remove the front brake hose bolt.
2 Disconnect the front brake hose.
3 Remove and discard the copper washers. Plug the front brake hose.
4. Remove the disc brake caliper.
1 Remove the disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6841
5. Inspect the disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. Install the disc brake caliper.
1 Install the disc brake caliper.
2 Install the disc brake caliper bolts.
2. Install the front brake hose.
^ Use new copper washers; connect the front brake hose.
^ Install the front brake hose bolt.
3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Check the brake system
for correct operation.
Caliper Disassembly and Assembly
Caliper
Disassembly
WARNING: Use of any brake fluid other than approved DOT 3 will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6842
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB
or equivalent meeting Ford specification ESA-M6C25A. ^
Do not reuse brake fluid drained or bled from the system.
^ Do not use brake fluid that has been stored in an open container.
^ Do not use contaminated brake fluid.
1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3.
Secure the disc brake caliper in a vise.
4. Remove the caliper pistons.
1 Place a block of wood between the caliper bridge and the caliper pistons.
2 Apply low air pressure to the fluid port in the disc brake caliper.
3 Force out the caliper piston to the block of wood.
4 Remove the block of wood and the caliper pistons.
5. Remove and discard the piston seals and boots.
6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.
If the caliper bores are excessively scored or corroded, install a new disc brake caliper.
Assembly
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6843
1. CAUTION: Never reuse piston seals or dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance
DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification
ESA-M6C25-A.
2. Install the caliper pistons.
1 Install the piston seal.
2 Install the piston boot.
3 CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston.
3. Install the disc brake caliper.
Brake Caliper Anchor Plate
Brake Caliper Anchor Plate
Removal
1. NOTE: 4x4 is shown, 4x2 is similar.
Remove the pads.
2. Remove the front disc brake caliper anchor plate.
1 Remove the two front disc brake caliper anchor plate bolts.
2 Remove the front disc brake caliper anchor plate.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6844
1. Install the front disc brake caliper anchor plate.
1 Position the front disc brake caliper anchor plate.
2 Install the front disc brake caliper anchor plate bolts.
2. Install the pads.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6845
Brake Caliper: Service and Repair Rear
Caliper Removal and Installation
Caliper
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly.
3. WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes
inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Do not clamp the brake hose. The hose can be damaged.
Disconnect the brake hose. 1
Remove the bolt.
2 Disconnect the rear wheel brake hose.
3 Remove the copper washers and plug the brake hose.
4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are
not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A
(Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-MlC171-A
for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in
contamination and accelerated corrosion or wear of the caliper slide pin mechanism.
Remove the rear disc brake caliper. 1
Remove the brake caliper bolts.
2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6846
5. Inspect the rear disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct
caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the
rear disc brake caliper.
Install the rear disc brake caliper.
2. Install the rear wheel brake hose.
^ Connect the brake hose and install the caliper flow bolt. Use new copper washers.
3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Verify correct brake
operation.
Caliper Disassembly and Assembly
Caliper
Disassembly
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6847
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake
caliper. 3. Secure the rear disc brake caliper in a vise.
4. Remove the rear disc brake piston.
1 Place a block of wood between the caliper bridge and the rear disc brake piston.
2 Apply low air pressure to the fluid port in the rear disc brake caliper.
3 Force the rear disc brake piston out to the block of wood.
4 Remove the block of wood and the rear disc brake piston.
5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the
rear disc brake caliper cylinder bore/piston is
excessively scored or corroded, install a new rear disc brake caliper.
Remove and discard the piston seal and dust boot.
Assembly
CAUTION: Never reuse the piston seal or dust boot.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6848
1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford
specification ESA-M6C25-A. ^
cylinder bore
^ piston seal
^ rear disc brake piston
^ dust boot
2. Install the piston seal.
3. Install the dust boot.
4. CAUTION: Be careful not to damage or dislodge the piston seal.
Install the rear disc brake piston.
5. Install the rear disc brake caliper.
Rear Disc Brake Adapter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6849
Adapter
Removal and Installation
1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft.
3. Remove the bolts and the rear wheel disc brake adapter. 4. To install, reverse the removal
procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Page 6850
Brake Caliper: Tools and Equipment
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications
Brake Fluid: Specifications
Brake Fluid High Performance DOT 3
Dot 4 may be used if Dot 3 is not available.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications > Page 6854
Brake Fluid: Description and Operation
Brake Fluid
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water to induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or
equivalent meeting Ford specification ESA-M6C25A. ^
Do not reuse brake fluid drained or bled from the system.
^ Do not use brake fluid that has been stored in an open container.
^ Do not use contaminated brake fluid.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 6858
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 6859
Brake Fluid Level Sensor/Switch: Description and Operation
Warning Switch, Brake Fluid Level
The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder
reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the
brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to
a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning
indicator to illuminate. Loss of brake fluid will cause this system to activate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications
Brake Hose/Line: Specifications
Front brake hose bolt 26 ft.lb
Front brake hose bracket 11 ft.lb
Rear brake hose to caliper bolt 26 ft.lb
Brake hose bracket to rear axle bolt 11 ft.lb
Front brake tube 13 ft.lb
Rear brake tube fitting 13 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Page 6863
Brake Hose/Line: Description and Operation
Brake Tubes and Hoses
CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which can
result in brake tube failure.
If a section of brake tube is damaged, a new section of the same type, size, shape and length must
be installed.
When installing hydraulic brake tubing, hoses, or connectors, tighten all connections to
specifications. After installation, bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Specifications
Brake Proportioning/Combination Valve: Specifications
Brake pressure control valve 13 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Hydraulic control unit (HCU) to bracket bolts 71 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 6870
Hydraulic Control Assembly - Antilock Brakes: Description and Operation
Hydraulic Control Unit
The HCU consists of the following components: ^
brake pressure control valve block
^ pump motor
New brake pressure control valve block and pump motor are installed as an assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 6871
Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 6872
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit
Removal and Installation
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector by lifting up on the release tab.
3. Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU.
1 Remove the bolts.
2 Remove the HCU.
5. If necessary, remove the anti-lock brake control module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 6873
6. CAUTION: After the electronic hydraulic control unit is installed, it is necessary to bleed the
hydraulic brake system.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications
Brake Master Cylinder: Specifications
Brake master cylinder tube fitting, front 11-14 ft.lb
Brake master cylinder tube fitting, rear 11-14 ft.lb
Master cylinder bleeder screw 70-159 in.lb
Brake master cylinder nut 17 ft.lb
Master cylinder brake tube nuts 13 ft.lb
Master cylinder bleeder screw 10 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 6877
Brake Master Cylinder: Description and Operation
Brake Master Cylinder
The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power
brake booster. The following conditions are considered normal and not indications that the brake
master cylinder is in need of repair or replacement: ^
Low brake fluid level detected without signs of leakage. This condition is caused by displacement
of brake fluid from the brake master cylinder reservoir into the disc brake calipers/rear disc brake
calipers to compensate for normal brake wear. Fill the brake master cylinder reservoir with High
Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting
Ford specification ESA-M6C25-A.
^ A momentary or slight squirt of brake fluid inside the brake master cylinder reservoir upon
application of the brake pedal.
^ A trace of brake fluid found on the outside of the power brake booster below the brake master
cylinder mounting flange. This condition results from the lubricating action of the brake master
cylinder wiping seal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 6878
Brake Master Cylinder: Testing and Inspection
Brake Master Cylinder
Normal Conditions
The following conditions are considered normal and are not indications that the brake master
cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder,
the fluid level in the brake master cylinder reservoir will rise during brake application and fall during
release. The net fluid level (after brake application and release) will remain unchanged. Condition
2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange.
This results from the normal lubricating action of the master cylinder bore and seal. Condition 3:
Fluid level will decrease with pad wear.
Abnormal Conditions
Changes in brake pedal feel or travel are indicators that something could be wrong in the brake
system. Refer to the Symptom Chart at Brakes and Traction Control/Testing and Inspection for
abnormal condition diagnosis.
Bypass Condition Test
1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake
master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master
cylinder has an internal leak and must be rebuilt or installed new.
Compensator Port Check
The purpose of the compensator ports in the brake master cylinder is to supply any additional
brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the
brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning
brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in
the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the
compensating ports are not plugged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 6879
Brake Master Cylinder: Adjustments
Push Rod Adjustment
1. Remove the brake master cylinder.
2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster.
Adjust the power brake booster to brake master cylinder push rod, vacuum applied. 1
Measure the power brake booster to brake master cylinder push rod.
2 If necessary, adjust the screw to the correct length.
3. Install the brake master cylinder.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Removal and Installation
Brake Master Cylinder: Service and Repair Removal and Installation
Master Cylinder
Removal and Installation
WARNING: Use of any other brake fluid than approved DOT 3 will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
1. On cruise control equipped vehicles, disconnect the brake pressure switch.
2. Disconnect the brake fluid level warning switch.
3. Disconnect the two brake lines, and plug the lines and the brake master cylinder ports.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Removal and Installation > Page 6882
4. Remove the wiring retainer clip from the master cylinder.
5. Remove the nuts and the brake master cylinder. 6. To install, reverse the removal procedure.
^ Bleed the brake master cylinder before installation.
^ Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Removal and Installation > Page 6883
Brake Master Cylinder: Service and Repair Brake Fluid Reservoir
Reservoir
Removal and Installation
WARNING: Use of any other brake fluid than approved DOT 3 will cause permanent damage to
brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycols ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
1. Disconnect the brake master cylinder fluid level warning switch. 2. Use a suitable suction device
to drain the brake master cylinder reservoir.
3. Carefully pry up on the brake master cylinder reservoir to remove.
4. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets.
Install the brake master cylinder reservoir. 1
Lubricate the two grommets with High Performance DOT 3 Motor Vehicle Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert
the grommets in the brake master cylinder.
2 Press the brake master cylinder reservoir into the grommets until it snaps.
3 Connect the brake master cylinder fluid level warning switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Removal and Installation > Page 6884
4 Fill the brake master cylinder reservoir with High Performance DOT 3 Motor Vehicle Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications
Wheel Cylinder: Specifications
Rear wheel cylinder bleeder screw 15 ft.lb
Rear wheel cylinder bolts 11 ft.lb
Brake line-to-rear wheel cylinder fitting 13 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Page 6888
Wheel Cylinder: Service and Repair
Wheel Cylinder
Removal and Installation
1. Remove the brake shoes and linings.
2. Remove the rear wheel cylinder.
1 Disconnect the brake line fitting.
2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder.
3. To install, reverse the removal procedure. 4. Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Specifications
Parking Brake Cable: Specifications
Parking brake cable and conduit clip bolt
...........................................................................................................................................................
11-14 ft lbs. Parking brake cable retainer clip bolt
.............................................................................................................................................................
54-70 inch lbs. Parking brake cable retainer screws ...........................................................................
.............................................................................................. 15 ft lbs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front
Parking Brake Cable: Service and Repair Cable and Conduit - Front
Cable and Conduit-Front
Removal
1. Remove the parking brake control.
2. Disconnect the front parking brake cable from the parking brake control.
3. Remove the front parking brake cable and conduit housing.
1 Compress the front parking brake cable and conduit-to-parking brake control clip.
2 Remove the front parking brake cable and conduit housing.
Installation
1. Follow the removal procedure in reverse order.
^ Make sure cable is routed through loop on take up spool.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6895
Parking Brake Cable: Service and Repair Cable and Conduit - Rear
Cable and Conduit-Rear
Removal
All vehicles
1. NOTE: Make sure the parking brake control is fully released.
Relieve the tension on the parking brake system. 1
Pull the front parking brake cable and conduit.
2 Insert a 4 mm (5/32-inch) drill bit or equivalent retainer into the parking brake control.
2. Remove the tire and wheel assembly.
3. NOTE: Disconnect the parking brake intermediate cable from the locating hole end of the
connector.
Disconnect the parking brake intermediate cable from the LH parking brake rear cable and conduit.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6896
4. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and
conduit at the parking brake cable equalizer.
Vehicles with drum brakes
5. Remove the screws.
All vehicles
6. Remove the RH parking brake rear cable and conduit to LH parking brake rear cable and conduit
clip.
7. Remove the RH parking brake rear cable and conduit from the parking brake cable bracket.
1 Compress the parking brake cable clip.
2 Remove the RH parking brake rear cable and conduit from the parking brake cable bracket.
Vehicles with rear disc brakes
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6897
8. Remove the RH parking brake rear cable and conduit from the rear parking brake cable retainer.
All vehicles
9. Remove the RH parking brake rear cable and conduit to the RH hydraulic brake line clip.
10. Remove the parking brake cable retainer clip.
1 Remove the parking brake cable retainer clip bolt.
2 Remove the parking brake cable retainer clip.
11. Unclip the parking brake rear cable and conduit from the brake line clip on top of the rear axle
housing.
Vehicles with rear disc brakes
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6898
12. Compress the retainer and release the parking brake rear cable and conduit from the rear disc
brake caliper anchor plate.
13. Unclip the parking brake rear cable and conduit from the parking brake lever. 14. Remove the
secondary brake shoe.
15. NOTE: It is not necessary to disconnect the parking brake lever from the brake shoe.
Disconnect the cable from the parking brake lever.
16. Compress the retainer and remove the cable and conduit.
Installation
Vehicles with rear disc brakes
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6899
1. Clip the parking brake rear cable and conduit to the parking brake lever.
2. Connect the parking brake rear cable and conduit to the rear disc brake caliper anchor plate.
Vehicles with rear drum brakes
3. Secure the brake cable retainer to the backing plate. 4. Install the secondary brake shoe.
All vehicles
5. Clip the parking brake rear cable and conduit to the brake line clip on top of the rear axle
housing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6900
6. Install the parking brake cable retainer clip.
1 Position the parking brake cable retainer clip.
2 Install the parking brake cable retainer clip bolt.
7. Install the RH parking brake rear cable and conduit to the RH hydraulic brake line clip.
Vehicles with rear disc brakes
8. Hook the RH parking brake rear cable and conduit to the rear parking brake cable retainer.
All vehicles
9. Connect the RH parking brake rear cable and conduit to the parking brake cable bracket.
1 Install the RH parking brake rear cable and conduit to the parking brake cable bracket.
2 Push the RH parking brake rear cable and conduit into the parking brake cable bracket until the
parking brake cable and conduit clip is seated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6901
10. Install the RH parking brake rear cable and conduit to the LH parking brake rear cable and
conduit clip.
Vehicles with rear drum brakes
11. Install the screws.
All vehicles
12. Connect the RH parking brake rear cable and conduit to the LH parking brake rear cable and
conduit at the parking brake cable equalizer.
13. Connect the parking brake intermediate cable to the LH parking brake rear cable and conduit.
14. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the front wheel and tire assemblies.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6902
15. Apply tension to the parking brake system.
1 Pull down on the front parking brake cable and conduit.
2 Remove the retainer from the parking brake control.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications
Parking Brake Control: Specifications
Parking brake control bolts ..................................................................................................................
............................................................... 13-17 ft lbs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 6906
Parking Brake Control: Service and Repair
Control
Removal
1. NOTE: Make sure the parking brake control is fully released.
Relieve the tension on the parking brake system. 1
Pull down on the parking brake intermediate cable.
2 Insert a 4 mm (5/32-inch) drill bit or equivalent retainer in the parking brake control.
2. Remove the LH front fender apron.
3. Remove the front parking brake cable and conduit from the retainer clip.
1 Remove the front parking brake cable and conduit retainer clip bolt.
2 Remove the front parking brake cable and conduit retainer clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 6907
4. NOTE: Disconnect the front parking brake cable and conduit at the locating hole end of the
connector.
Disconnect the front parking brake cable and conduit from the parking brake intermediate cable.
5. Remove the front parking brake cable and conduit from the bucket.
1 Compress the retainer from the front parking brake cable and conduit from the bracket.
2 Remove the front parking brake cable and conduit from the bracket.
6. Remove the parking brake release mounting bolts.
7. Remove the parking brake control and front parking brake cable and conduit.
1 Disconnect the parking brake signal switch electrical connector.
2 Remove the three parking brake control bolts.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 6908
1. Follow the removal procedure in reverse order.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications
Parking Brake Shoe: Specifications
Parking brake shoes and lining minimum thickness 0.04 in
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 6912
Parking Brake Shoe: Service and Repair
Shoes
Removal
1. NOTE: Make sure the parking brake control is fully released.
Relieve the tension on the parking brake system. 1
Pull the front parking brake cable and conduit.
2 Insert a 4 mm (5/32-inch) drill bit or equivalent retainer.
2. Raise and support the vehicle. 3. Remove the tire and wheel assembly.
4. Remove the rear brake disc.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 6913
5. Remove the brake shoe retracting spring.
6. Remove the brake shoe adjusting screw spring.
7. Remove the brake adjuster screw.
8. Remove the rear brake shoe hold-down springs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 6914
9. Remove the rear brake shoes and linings along with the inboard brake shoe retracting spring.
10. Inspect the components for excessive wear or damage and install new as required.
Installation
1. NOTE: Lubricate the brake shoe contact point before installation of rear shoes using Silicone
Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford
specification ESE-MIC171-A.
Install the rear brake shoes and linings along with the inboard brake shoe retracting spring.
2. Install the brake shoe hold-down springs.
3. Install the brake adjuster screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 6915
4. Install the brake shoe adjusting screw spring.
5. Install the outboard brake shoe retracting spring.
6. Use Brake Adjusting Gauge to measure the inside diameter of the drum portion of the rear brake
disc.
7. Use Brake Adjusting Gauge to set the rear brake shoe and lining diameter to 0.5 mm (0.020
inch) less than the inside diameter of the drum portion
of the rear brake disc.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 6916
8. Install the rear brake disc.
9. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting
surfaces of the wheel or the surface of the wheel
hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal to
metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and come off
while the vehicle is in motion, causing loss of control.
Clean the wheel hub mounting surface.
10. Install the wheel and tire assembly.
11. Apply tension to the parking brake cable system.
1 Hold the front parking brake cable and conduit taut.
2 Remove the retainer from the parking brake control.
12. Check operation of the parking brake.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 6917
Parking Brake Shoe: Tools and Equipment
Special Service Tool(s)
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications
Vacuum Brake Booster: Specifications
Power brake booster push rod length 0.99-1.01 in
Power brake booster nuts 15-20 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6925
Vacuum Brake Booster: Description and Operation
Brake Booster
The power brake booster: ^
is a dual diaphragm, vacuum assisted power brake booster.
^ is located on the RH side of the bulkhead in the engine compartment, between the brake pedal
and brake master cylinder.
^ is divided into separate chambers by the diaphragm.
^ will not operate if vacuum is restricted or if any of the vacuum related power brake components
fail.
^ is installed as an assembly.
If the power assist fails, the brake system will continue to operate with increased brake pedal effort.
Hose and Check Valve
The power brake booster check valve: ^
is located on the front of the power brake booster.
^ is positioned between the power brake booster and the power brake booster hose.
^ closes when the engine is turned off.
^ in the closed position, traps engine vacuum in the power brake booster.
^ retains vacuum to provide several power assisted brake applications with the engine off.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6926
Vacuum Brake Booster: Testing and Inspection
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in
NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several
times to exhaust all
vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system
is operating, the brake pedal will tend to move
downward under constant foot pressure. If no motion is felt, the power brake booster system is not
functioning. Continue the test with the following steps.
4. Remove the vacuum booster hose from check valve connection. Manifold vacuum must be
available at the check valve end of the vacuum booster
hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is
available to the power brake booster, connect the vacuum booster hose to the power brake booster
check valve and repeat Steps 2 and 3 above.
5. Check and if no downward movement of the brake pedal is felt, install a new power brake
booster. 6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the
vehicle stand for 10 minutes. Then apply the brake pedal with
approximately 89 N (20 lbs.) of force. The brake pedal feel should be the same as that noted with
the engine operating. If the brake pedal feels hard (no power assist), install a new check valve and
retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6927
Vacuum Brake Booster: Service and Repair
Brake Booster
Removal
1. Remove the brake master cylinder.
2. Disconnect the power broke booster hose.
1 Compress the clamp.
2 Disconnect the power brake booster hose.
3. Disconnect the brake pedal to power brake booster push rod.
1 Remove the self-locking pin.
2 Remove the stoplight switch and the brake booster push rod from the brake pedal pin.
3 Remove the brake booster push rod bushing.
4. Remove the bulkhead sound insulator.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6928
5. NOTE: Support the power brake booster.
Remove the power brake booster. 1
Remove the nuts.
2 Remove the power brake booster.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Description and Operation
Vacuum Brake Booster Check Valve: Description and Operation
Hose and Check Valve
The power brake booster check valve: ^
is located on the front of the power brake booster.
^ is positioned between the power brake booster and the power brake booster hose.
^ closes when the engine is turned off.
^ in the closed position, traps engine vacuum in the power brake booster.
^ retains vacuum to provide several power assisted brake applications with the engine off.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Description and Operation > Page 6932
Vacuum Brake Booster Check Valve: Testing and Inspection
Check Valve
The function of the power brake booster check valve is to allow manifold vacuum to enter the
power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during
sustained full throttle operation. To test the function of the power brake booster check valve: ^
Start and run the engine for at least 10 seconds.
^ Operate the brake pedal to check for power assist.
^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the power
brake booster check valve from the power brake booster.
^ There should be enough vacuum retained in the power brake booster for at least one more
power-assisted brake Operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake
Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set
Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON DTCB2607 May Be
Set
Article No. 01-6-1
04/02/01
^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
FORD: 2001 EXPLORER
ISSUE
The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607
may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp
may remain on or may illuminate intermittently. This may be due to the ABS module remaining
active when the engine is cranked and both blower motors are on.
ACTION
Replace the ABS module with an updated module if existing module is the original design, and
check for proper circuit grounding. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
It the ABS lamp is on intermittently:
1. Replace the ABS module.
a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Test drive vehicle to verify repair.
If the ABS lamp is on continuously:
1. Replace the ABS module.
a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 3.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake
Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6942
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
3. Verify if the vehicle is a 4X4 or 4X2.
^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded.
^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary.
4. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 5.
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 301000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set
Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON
DTCB2607 May Be Set
Article No. 01-6-1
04/02/01
^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC
TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES
ONLY
FORD: 2001 EXPLORER
ISSUE
The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607
may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp
may remain on or may illuminate intermittently. This may be due to the ABS module remaining
active when the engine is cranked and both blower motors are on.
ACTION
Replace the ABS module with an updated module if existing module is the original design, and
check for proper circuit grounding. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
It the ABS lamp is on intermittently:
1. Replace the ABS module.
a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Test drive vehicle to verify repair.
If the ABS lamp is on continuously:
1. Replace the ABS module.
a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer
Workshop Manual, Section 206-09 for installation instructions.
2. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 3.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6948
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
3. Verify if the vehicle is a 4X4 or 4X2.
^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded.
^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary.
4. Turn the key to the Run position for 5 seconds.
a. If ABS lamp remains on after bulb check, continue with Step 5.
b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair.
5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 301000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6949
Electronic Brake Control Module: Specifications
Control module bolts 13 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6950
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6951
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6952
Electronic Brake Control Module: Description and Operation
Anti-Lock Brake Control Module
NOTE: The new anti-lock brake control module must be reconfigured upon installation.
The anti-lock brake control module is mounted to the HCU. It is an on-board diagnostic,
non-repairable unit consisting of two microprocessors and the necessary circuitry for their
operation. The anti-lock brake control module monitors system operation during normal driving as
well as during anti-lock braking. Anti-lock brake module operation is as follows: ^
Under normal driving conditions, the microprocessor produces short test pulses to the solenoid
valves that check the electrical system without any mechanical reaction.
^ Impending wheel lock conditions trigger signals from the anti-lock brake control module that open
and close the appropriate solenoid valves. This results in moderate pulsations in the brake pedal.
During normal braking, the brake pedal feel will be identical to a standard brake system. Most faults
that occur in the anti-lock brake system will be stored as a diagnostic trouble code (DTC) in the
keep-alive memory of the anti-lock brake control module. The DTCs can be retrieved by following
the on-board diagnostic procedures.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6953
Electronic Brake Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6954
Electronic Brake Control Module: Service and Repair
Module-Anti-Lock Brake Control
Removal and Installation
1. Disconnect the battery ground cable.
2. Disconnect the electrical connectors.
3. Remove the anti-lock brake control module.
1 Remove the bolts.
2 Remove the anti-lock brake control module.
4. CAUTION: Once the new module is installed, the module configuration information may have to
be entered.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6959
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6960
Brake Fluid Level Sensor/Switch: Description and Operation
Warning Switch, Brake Fluid Level
The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder
reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the
brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to
a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning
indicator to illuminate. Loss of brake fluid will cause this system to activate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations > Page 6964
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > Front
Wheel Speed Sensor: Specifications
Front anti-lock brake sensor bolt (4x2) 8.5 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > Front > Page 6972
Wheel Speed Sensor: Specifications
Rear anti-lock brake sensor bolt 20 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Left front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Left front > Page 6975
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front > Page 6978
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front > Page 6979
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Page 6980
Wheel Speed Sensor: Description and Operation
Anti-Lock Brake Sensor
NOTE: Any time an anti-lock brake sensor is removed, thoroughly clean the mounting surfaces. On
front anti-lock brake sensors, apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease
E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.
The anti-lock brake system uses three variable-reluctance sensors to determine vehicle speed. The
anti-lock brake sensors operate on magnetic induction principle. As the teeth on the anti-lock brake
sensor indicator rotate past the stationary sensor, a signal proportional to the speed of the rotation
is generated and sent to the anti-lock brake control module through a twisted cable and shielded
wiring harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Rear Antilock Control
Wheel Speed Sensor: Service and Repair Rear Antilock Control
Sensor-Rear
Removal and Installation
1. Raise and support vehicle.
2. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake
sensor before removal.
Remove the rear anti-lock brake sensor. 1
Disconnect the rear anti-lock brake sensor electrical connector.
2 Remove the bolt.
3 Remove the rear anti-lock brake sensor.
3. NOTE: Thoroughly clean the mounting surface.
NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE
75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford
specification WSL-M2C192-A.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 6983
Wheel Speed Sensor: Service and Repair Sensor, Front
Sensor-Front 4x2
Removal and Installation
1. Raise and support the vehicle.
2. Disconnect the front anti-lock brake sensor wire from the vehicle frame.
1 Disconnect the electrical connector.
2 Unclip the front anti-lock brake sensor wire from the vehicle frame.
3. Remove the front anti-lock brake sensor.
1 Remove the bolt.
2 Remove the front anti-lock brake sensor.
4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply
High-Temperature 4x4 Front Axle and Wheel Bearing
Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 6984
Wheel Speed Sensor: Service and Repair Sensor, Rear
Sensor-Rear
Removal and Installation
NOTE: The rear anti-lock brake sensor indicator is attached to the differential case.
For additional information, refer to Transmission and Drivetrain; Differential.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder-Functional Lock Cylinder
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
3. To install, reverse the removal procedure.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
6995
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder
Removal and Installation
1. NOTE: Make sure the front wheels are in the straight-ahead position.
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and
instructions in the steering wheel
removal and installation procedure.
Remove the steering wheel assembly.
3. Twist off the cap from the ignition switch cylinder.
4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock
repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to
build the new lock cylinder to the current key code of the vehicle.
Remove the ignition switch lock cylinder. ^
Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch
lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the
steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
6996
5. Remove the bearing retainer.
6. Remove the bearing and gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
7. To install, reverse the removal procedure.
^ Install a new ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 7000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 7005
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 7006
Starter Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 7007
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Battery - Battery Eye Function/Charging/Service
Battery: Technical Service Bulletins Battery - Battery Eye Function/Charging/Service
TSB 07-5-8
03/19/07
BATTERY SERVICE - OPERATION OF BATTERY EYE - CHARGING SERVICE TIPS
FORD: 1999-2003 Escort 2000-2006 Taurus 2000-2007 Crown Victoria, Focus, Mustang
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 2000-2003
Windstar 2000-2004 Explorer Sport 2000-2006 Excursion 2000-2007 E-Series, Expedition,
Explorer, F-150, F-250 Light Duty, F-53 Motorhome Chassis, F-Super Duty, Ranger 2001-2003
Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004-2006 Freestar 2005-2007 Escape
Hybrid 2007 Edge 2000-2007 F-650, F-750 2006 Low Cab Forward
LINCOLN: 1998-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007
MKZ 2000-2007 Navigator 2002 Blackwood 2003-2005 Aviator 2006-2007 Mark LT, Mark LT 2007
MKX
MERCURY: 1999-2002 Cougar 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego
2006-2007 Milan 2000-2002 Villager 2000-2007 Mountaineer 2004-2006 Monterey 2004-2007
Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 06-4-2 to update the vehicle model years.
ISSUE This TSB describes the operation and function of the Battery Eye and correct Battery
Recharging procedures.
ACTION Refer to the following Service Tips to avoid misdiagnosis of a battery using the Battery
Eye, and to determine the best way to charge a battery that may be discharged.
SERVICE TIPS
Battery Eye Operation / Function
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Battery - Battery Eye Function/Charging/Service > Page 7012
The purpose of the battery eye is to indicate the state of charge of the battery in the assembly plant
and while on the dealership lot. The battery eye can also indicate the state-of-charge when the
vehicle is delivered to the dealership and during the pre-delivery inspection process. The battery
eye is made up of a viewing plate, two balls and a small passage. The balls indicate the specific
gravity of the electrolyte by floating higher or lower in the passageway. It is important to note that
the battery eye checks the specific gravity on only one battery cell.
^ RED usually indicates that the battery state-of-charge is at 40 percent or less
^ YELLOW indicates that the battery state-of-charge is between 40 and 57 percent
^ GREEN indicates that the battery state-of-charge is above 57 percent
^ NO COLOR/BLACK sometimes no color can be seen at all and the eye appears black. This could
happen after the battery has been in service for several years and some of the plate material has
coated the balls
^ CLEAR could happen if the battery case becomes damaged and the electrolyte has fallen below
the plates
The battery eye is a state-of-charge indicator, but should not be used to condemn a battery after
the vehicle has been placed in service. After delivery, many things could happen to cause the
battery eye to lead to misdiagnosis of the battery's actual state-of-charge. After the vehicle has
been in service, the battery eye does not always accurately reflect the battery state-of-charge. The
GR-1 190 Battery Tester/Charge or Micro 490 Digital Battery Analyzer should be used to determine
battery condition.
Do not replace a battery based solely on the indication given by the battery eye. The battery eye
color simply indicates the battery state-of-charge, not its condition. If the eye indicates the battery
may be discharged, Use GR-1 190 Battery Tester/Charger to determine the battery condition or
recharge the battery before testing using the Micro 490.
A red or yellow indicator usually means that the battery is discharged, not defective. Therefore, a
battery with a red or yellow eye should not automatically be replaced. The indicator could remain
red after recharge because the balls are stuck in the passageway.
When new vehicles are delivered to the dealership, be sure to check the state-of-charge indicator
within 72 hours. If the battery eye is red, charge the battery until it is fully charged. Refer to the
following Battery Charging Procedure.
Batteries discharge while the vehicle is on the lot due to normal parasitic key-off loads. Also,
vehicles in inventory are generally driven short distances with heavy electrical loads. Over a period
of time (30 days or more), vehicles still in inventory will have shallow to deeply discharged
batteries. The vehicle's charging system is designed to supply the vehicle's electrical power needs
and maintain the battery near full charge during normal vehicle use. The charging system is not
capable of bringing a deeply discharged battery back near full charge in a short amount of time
such as allowing the vehicle to idle for 15 minutes to "recharge the battery". Discharged batteries
should be charged using an external charger. Refer to the following Battery Charging Procedure.
NOTE
THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS),
EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY
MIXED.
Battery Charging Procedure
Dealers with GR-1 190, use the Diagnostic Fast Charge Mode on GR-1 190 for this procedure and
for dealers without a GR-1 190 the following procedure applies:
The Micro 490 Digital Battery Analyzer (Rotunda Part Number 162-00004) is extremely accurate if
used properly and can distinguish the difference between good, defective, worn out, or
discharged-only batteries. This TSB provides proper battery charging procedures for batteries that
are identified as "discharged-only". Discharged-only batteries can be recharged using the
procedures in this TSB without reducing battery life or charge capacity.
NOTE
BATTERY CHARGERS HAVE IMPROVED GREATLY WITH THE ADDITION OF THE NEW
GENERATION OF "PULSE CHARGERS". THESE NEW CHARGERS PULSE CURRENT INTO
THE BATTERY THAT BREAKS DOWN THE SULFATION LAYER ON THE BATTERY PLATES
AND GENERALLY REDUCE CHARGING TIMES TO LESS THAN 1 HOUR.
^ DEEPLY DISCHARGED - A battery that is drained over a prolonged period of time such as an
unsold vehicle, to the point it is dead
^ SHALLOW DISCHARGE - A battery that is drained by leaving an accessory on for several hours
or a few days, and has a very low charge
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Battery - Battery Eye Function/Charging/Service > Page 7013
The chart information summarizes two (2) recommended methods of charging.
NOTE
COLD BATTERIES WILL NOT READILY ACCEPT A CHARGE. THEREFORE, BATTERIES
SHOULD BE ALLOWED TO WARM TO APPROXIMATELY 41° F (5° C) BEFORE CHARGING.
THIS MAY REQUIRE 4 TO 8 HOURS AT ROOM TEMPERATURE.
A battery which has been completely discharged and left in that condition for a prolonged time
(such as an unsold vehicle) may be slow to accept a charge initially, and in some cases may not
accept a charge at the normal charger setting. When batteries are in this condition, charging can
be started by use of the "dead battery" feature on chargers so equipped. Follow charger
manufacturer's instructions for use of dead battery switch. If switch is the spring-loaded type, it may
need to be held in the ON position for up to 3 minutes.
NOTE
THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS),
EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY
MIXED.
For additional information, refer to the PTS Website, web based Technician training "Fix It Right
The First Time" course "Battery Testing and Charging 34G02W0" (website).
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT070508 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
10655 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical
Specifications
Battery: Electrical Specifications
Battery/Alternator Specifications
Parasitic Draw (Current Drain) Less Than 0.05 amps
For testing procedures, please refer to Battery Drain Test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical
Specifications > Page 7016
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Page 7017
Battery: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Technician
Safety Information
Battery: Technician Safety Information
WARNING:
^ DO NOT ATTEMPT THIS LEST ON A LEAD-ACID BATTERY THAT HAS RECENTLY BEEN
RECHARGED. EXPLOSIVE GASES CAN CAUSE PERSONAL INJURY.
^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL
INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO
COME NEAR THE BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES.
ALWAYS PROVIDE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER
SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR INSTALLING ANY FRONT OR SIDE
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE
REPAIRING, INSTALLING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR
SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR
LATCHES, STRIKERS, SEATS AND HOOD LATCHES. FAILURE TO FOLLOW THESE
PROCEDURES MAY RESULT IN PERSONAL INJURY.
REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF
THE FRONT AIR BAG SENSORS.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED). FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE
ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH
A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ KEEP OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID
CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING
NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID
SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY
WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF
ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Technician
Safety Information > Page 7020
Battery: Vehicle Damage Warnings
CAUTION: To prevent damage to the meter, do not crank the engine or operate accessories that
draw more than 10A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Page 7021
Battery: Description and Operation
Environmental Protection
Vehicles are equipped with a 12 volt maintenance-free battery.
The battery and cable system consists of the following components:
^ battery
^ battery cable assembly
^ battery tray
Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized
recycling facility for disposal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Battery: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the system.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
a concern is found, correct the cause before proceeding to the next step. 4. If the fault is not
visually evident, proceed to the pinpoint test. See: Pinpoint Tests
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 7024
A1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 7025
Battery: Component Tests and General Diagnostics
Battery Drain Test
NOTE: No production vehicle should have more than a 50 mA (0.050 amp) continuous draw.
Check for current drains on the battery in excess of 50 milliampere (0.050 amp) with all the
electrical accessories off and the vehicle at rest. Current drains can be tested with the following
procedure:
WARNING: DO NOT ATTEMPT THIS LEST ON A LEAD-ACID BATTERY THAT HAS RECENTLY
BEEN RECHARGED. EXPLOSIVE GASES CAN CAUSE PERSONAL INJURY.
CAUTION: To prevent damage to the meter, do not crank the engine or operate accessories that
draw more than 10A.
NOTE:
^ Many modules draw 10 mA (0.010 amp) or more continuously.
^ Use an in-line ammeter between the battery positive or negative post and its respective cable.
^ Typically, a drain of approximately one amp can be attributed to an engine compartment lamp,
glove compartment lamp, or luggage compartment lamp staying on continually. Other component
failures or wiring shorts may be located by selectively pulling fuses to pinpoint the location of the
current drain. When the current drain is found, the meter reading will fall to an acceptable level. If
the drain is still not located after checking all the fuses, it may be due to the generator.
^ To accurately test the drain on a battery, an in-line digital ammeter must be used. Use of a test
lamp or voltmeter is not an accurate method due to the number of electronic modules.
1. Make sure the junction box/fuse panels are accessible without turning on interior and underhood
lights. 2. Drive the vehicle at least five minutes and over 48 km/h (30 mph) to turn on and exercise
the vehicle systems. 3. Allow the vehicle to sit with the key off for atleast 40 minutes to allow
modules to time out/power down. 4. Connect a fused jumper wire between the negative battery
cable and the negative battery post to prevent modules from resetting and to catch
capacitive drains.
5. Disconnect the negative battery cable from the post without breaking the connection of the
jumper wire. 6. Connect the tester between the negative battery cable and the post. The meter
must be capable of reading milliampere and should have a 10 amp
capability.
NOTE: It is very important that continuity is not broken between the battery and the negative
battery cable when connecting the meter. If this happens, the entire procedure must be repeated.
7. Remove the jumper wire.
NOTE: If the meter settings need to be switched or the test leads need to be moved to another
jack, the jumper wire must be reinstalled to avoid breaking continuity.
NOTE:
^ Amperage draw will vary from vehicle to vehicle depending on the equipment package. Compare
to a comparable vehicle for reference.
^ No production vehicle should have more than a 50 mA (0.050 amp) draw.
8. If the draw is found to be excessive, pull fuses from the battery/central junction box one at a time
and note the current drop. Do not reinstall the
fuses until you are finished testing.
9. Check the wiring schematic in the wiring diagram for any circuits that run from the battery without
passing through the battery/central junction box
. Disconnect these circuits if the draw is still excessive.
Battery Load Test
1. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on
high beam. 2. Increase the engine speed to approximately 2,000 rpm. The voltage should increase
a minimum of 0.5 volt above the base voltage.
^ If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests. See:
Charging System/Testing and Inspection/Component Tests and General Diagnostics/Generator
Testing
^ If the voltage increases as specified, the charging system is operating normally.
Electronic Drains That Shut Off When The Battery Cable Is Disconnected
1. Repeat the steps of the battery drain testing. 2. Make sure all doors are closed and accessories
are off. Without starting the engine, turn the ignition switch to RUN for a moment and then OFF.
Wait a few minutes for the illuminated entry lamps to turn off if equipped.
3. Connect the ammeter and read the amperage draw.
Test Conclusion
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 7026
The current reading (current drain) should be less than 50 mA (0.05 amp). If the current drain
exceeds 50 mA (0.05 amp) after a few minutes, and if this drain did not show in previous tests, the
drain is most likely caused by an inoperative electronic component. As in previous tests, remove
the fuses from the battery/central junction box one at a time to locate the problem circuit.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 7027
Battery Analyzer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Removal and
Installation
Battery: Service and Repair Removal and Installation
Battery
REMOVAL
1. Disconnect the battery cables.
2. Remove the battery heat shield.
3. Remove the hold-down bolt and the bracket.
4. Remove the battery.
WARNING: WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS
COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL
INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE
CORNERS.
INSTALLATION
1. To install, reverse the removal procedure.
Battery Tray
REMOVAL
1. Remove the battery.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Removal and
Installation > Page 7030
2. Remove the battery ground cable to battery tray pin-type retainer.
3. Remove the cable to battery tray pin-type retainer.
4. Remove the bolt and the nut.
5. Remove the battery tray.
1 Remove the bolt.
2 Remove the battery tray.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Removal and
Installation > Page 7031
Battery: Service and Repair Battery Disconnect
WARNING:
^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL
INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO
COME NEAR THE BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES.
ALWAYS PROVIDE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER
SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR INSTALLING ANY FRONT OR SIDE
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE
REPAIRING, INSTALLING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR
SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR
LATCHES, STRIKERS, SEATS AND HOOD LATCHES. FAILURE TO FOLLOW THESE
PROCEDURES MAY RESULT IN PERSONAL INJURY.
REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF
THE FRONT AIR BAG SENSORS.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED). FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE
ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH
A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ KEEP OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID
CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING
NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID
SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY
WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF
ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
1. Disconnect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn
its strategy.
2. Disconnect the positive battery cable. 3. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Page 7032
Battery Analyzer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
Generator Output (Minimum) 58 A at 2,000 rpm
Generator Output 13.0 - 15.0 V at 2,000 rpm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications > Page 7038
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions
Alternator: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7041
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7042
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7043
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7044
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7045
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7046
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7047
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7048
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7049
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7050
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7051
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7052
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7053
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7054
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7055
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7056
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7057
Alternator: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7058
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7059
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 7060
Alternator: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 7061
Alternator: Description and Operation
The generator system consists of:
^ generator
^ battery
^ wiring harness
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Generator Testing
Alternator: Testing and Inspection Generator Testing
CAUTION:
^ To prevent damage to the generator, do not make the jumper wire connections except as
directed.
^ Do not allow any metal object to come in contact with the housing and the internal diode cooling
fins with key on or off. A short circuit will result and burn out the diodes.
NOTE:
^ Battery posts and cable clamps must be clean and tight for accurate meter indications.
^ Refer to the battery tester manual for complete directions for testing the charging system.
1. Turn off all lamps and electrical components. 2. Place the transmission range selector lever in
NEUTRAL and apply the parking brake. 3. Carry out the Load Test and No-Load Test according to
the following component tests:
Generator On-Vehicle Tests-Load Test
1. Switch the battery tester to the ammeter function. 2. Connect the positive and negative leads of
the battery tester to the corresponding battery terminals. 3. Connect the current probe to the
generator B+ output terminal, circuit 38 (BK/OG). 4. With the engine running, turn the A/C on, the
blower motor on high speed and the headlamps on high beam. 5. Increase the engine speed to
approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base
voltage.
^ If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests.
^ If the voltage increases as specified, the charging system is operating normally.
6. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the
generator. Generator output should be at least 58
amps.
Generator-On Vehicle Test-No-Load Test
1. Switch the battery tester to the voltmeter function. 2. Connect the voltmeter positive lead to the
generator B+ output terminal, circuit 38 (BK/OG) and the negative lead to ground. 3. Turn all
electrical accessories off. 4. With the engine running at 2,000 rpm, check the generator output
voltage. The voltage should be between 13.0 and 15.0 volts. If not, refer to the
Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Generator Testing > Page 7064
Alternator: Testing and Inspection Other Diagnosis and Testing
For further information regarding the diagnosis of this component, please refer to Charging System;
Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Page 7065
Alternator: Service and Repair
REMOVAL
1. Disconnect the battery. 2. Remove the air cleaner outlet tube. 3. Remove the drive belt.
4. Disconnect the wiring harness to voltage regulator electrical connector.
5. Remove the B+ terminal cover.
6. Remove the B+ terminal electrical connector.
1 Remove the B+ terminal nut.
2 Disconnect the B+ terminal electrical connector.
7. Remove the wiring harness-to-generator pin-type retainer.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and
Inspection > Page 7066
8. Remove the generator.
1 Remove the stud bolts and nut.
2 Remove the generator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder-Functional Lock Cylinder
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
3. To install, reverse the removal procedure.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7076
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder
Removal and Installation
1. NOTE: Make sure the front wheels are in the straight-ahead position.
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and
instructions in the steering wheel
removal and installation procedure.
Remove the steering wheel assembly.
3. Twist off the cap from the ignition switch cylinder.
4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock
repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to
build the new lock cylinder to the current key code of the vehicle.
Remove the ignition switch lock cylinder. ^
Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch
lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the
steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7077
5. Remove the bearing retainer.
6. Remove the bearing and gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
7. To install, reverse the removal procedure.
^ Install a new ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 7081
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component
Information > Testing and Inspection
Starter Drive/Bendix: Testing and Inspection
Starter Drive and Flywheel Ring Gear Inspection
1. Remove the starter motor. Refer to Starter Motor.
2. Check the wear patterns on the starter drive gear and the flywheel ring gear. If the wear pattern
is abnormal, install a new starter motor, refer to
Starter Motor.
3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are
scored or damaged, install a new starter motor,
refer to Starter Motor. If necessary, install a new flywheel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 7089
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 7090
Starter Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 7091
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7097
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7098
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7099
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7100
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7101
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7102
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7103
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7104
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7105
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7106
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7107
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7108
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7109
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7110
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7111
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7112
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7113
Auxiliary Power Outlet: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7114
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7115
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7116
Auxiliary Power Outlet: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 7117
Diagram 501-12-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Page 7118
Auxiliary Power Outlet: Service and Repair
PANEL - POWER POINT
Removal and Installation
1. Disconnect the battery ground cable
2. Remove the screws and position the power point receptacle and panel aside.
3. Disconnect the power point receptacle electrical connector.
4. Remove the power point receptacle from the panel.
1. Remove the screws. 2. Remove the power point receptacle.
5. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7127
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7128
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7129
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7130
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7131
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7132
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7133
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7134
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7140
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7141
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7142
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7143
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7144
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7145
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7146
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7147
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Page 7148
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7153
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7154
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7155
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7156
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7157
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7158
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7159
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7160
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7161
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7162
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7163
Fuse: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7164
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7165
Fuse: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7166
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7167
Fuse: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7168
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7171
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7172
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7173
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7174
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7175
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7176
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7177
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7178
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7179
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7180
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7181
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7182
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7183
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7184
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7185
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7186
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7187
Fuse: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7188
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7189
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7192
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7193
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7194
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7195
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7196
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7197
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7198
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7199
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7200
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7201
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7202
Fuse: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7203
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7204
Fuse: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7205
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7206
Fuse: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7207
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7212
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7213
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7214
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7215
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7216
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7217
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7218
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7219
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7220
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7221
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7222
Fuse Block: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7223
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7224
Fuse Block: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7225
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7226
Fuse Block: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7227
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7230
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7231
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7232
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7233
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7234
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7235
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7236
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7237
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7238
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7239
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7240
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7241
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7242
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7243
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7244
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7245
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7246
Fuse Block: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7247
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7248
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7249
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7252
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7253
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7254
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7255
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7256
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7257
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7258
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7259
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7260
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7261
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7262
Fuse Block: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7263
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7264
Fuse Block: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7265
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7266
Fuse Block: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7267
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection > Page 7271
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection > Page 7275
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7280
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7281
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7282
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7283
Multiple Junction Connector: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7284
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7285
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7286
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7287
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7288
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7289
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7290
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7291
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7292
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7293
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7294
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7295
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7296
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110 > Page 7297
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7302
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7306
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7311
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7312
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7313
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7314
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7315
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7316
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7317
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7318
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7319
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7320
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7321
Relay Box: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7322
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7323
Relay Box: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7324
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7325
Relay Box: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7326
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7329
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7330
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7331
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7332
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7333
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7334
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7335
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7336
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7337
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7338
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7339
Relay Box: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7340
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7341
Relay Box: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7342
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7343
Relay Box: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7344
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7349
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7350
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7351
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7352
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7353
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7354
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7355
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7356
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7357
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7358
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7359
Relay Box: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7360
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7361
Relay Box: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7362
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7363
Relay Box: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7364
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7367
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7368
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7369
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7370
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7371
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7372
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7373
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7374
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7375
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7376
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7377
Relay Box: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7378
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7379
Relay Box: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7380
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7381
Relay Box: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7382
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips
Technical Service Bulletin # 05-18-7 Date: 050922
Electrical - Wiring Soldering/Crimping Service Tips
TSB 05-18-7
09/22/05
WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS
FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006
Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005
Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005
Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006
F-650, F-750 2006 Low Cab Forward
LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood
2003-2005 Aviator 2006 Mark LT
MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego
2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model
years.
ISSUE Wire harness repairs are supported through the availability of individual components such
as:
^ Wire terminals with machine crimped pigtails
^ Hard shell connectors
^ Dual wall heat shrink tubing
^ Complete, loaded, wiring pigtail kits
Some of the available tools and service parts that are helpful when performing wiring harness
repairs are:
^ Motorcraft Wiring Pigtail Catalog (see website for more information)
^ Rotunda Wire Splice Tool kit 164-R5903
^ General Wire Terminal Repair Kit (order through Ford Component Sales)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7387
Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15
web site. To access on PTS:
^ Select the year/model of the vehicle on the P15 home page
^ Select the wiring tab
^ Select the link to the pigtail or terminal repair kit at the top right of screen.
Additional service information contained in this TSB detailing wire folding, soldering, and crimping
techniques may be helpful.
ACTION
REPAIR VS REPLACEMENT
The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell
connectors when available. The only exceptions to this procedure are when:
^ The repair cost exceeds the cost to replace the wiring harness
^ There are no component parts released to service the wiring harness
RESTRAINTS RELATED WIRING REPAIRS
If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair
them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford
Motor Company publication.
If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401,
14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified
in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with
white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits
with gold plated terminals are also available in the parts catalog.
Disclaimer
Service Tips
Refer to applicable model year wiring diagrams for circuit information.
Twisted Wire Circuits
For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51
mm) Twist the repaired wires in the same direction and with the same general twist rate as the
original wiring. Reapply the shielding on shielded circuits.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7388
Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2).
Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed
(Figure 2). Silicone must not be used.
Excess wire from the harness can be folded back on itself to maintain the harness length.
Reapply any convolute and tape that was removed to make the repair.
For 16 AGW and Smaller Diameter Wire
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7389
1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2,
taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled
at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut
off the end and re-strip.
2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced.
Twist wires together. Solder wires together (Figure 4).
NOTE
USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER
FOR WIRE REPAIR.
3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond.
NOTE
WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES.
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7390
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7391
4. Evenly position heat shrink tubing over wire repair (Figure 5).
NOTE
OVERLAP TUBING ON BOTH WIRES.
5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt
appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the
hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between
the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the
solder point (Figure 5).
For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs)
1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs
can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire
is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during
stripping, cut off the end and re-strip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7392
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7393
NOTE
THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN
HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE
FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP
LENGTHS AND FOLDING TECHNIQUES.
2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4
mm) away from stripped end (Figure 6).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7394
3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or
equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice
(Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles
together until the ratchet releases, then allow the jaws of the tool to open fully.
4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to
place the brazed seam of the butt splice toward the indenter (Figure 8).
5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages
sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the
butt splice.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7395
6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt
splice (Figure 8).
7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool
handles to open, then remove crimped butt splice.
8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping
chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool
around.
9. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly
off center, but not off the end of the buff splice (Figure 9-a).
b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of
buff splice (Figure 9-b).
c. Wire is visible through inspection hole of splices (Figure 9-c).
10. Evenly position heat shrink tubing over wire repair (Figure 5).
NOTE
OVERLAP TUBING ON BOTH WIRES.
11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt
appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the
hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between
the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the
solder point (Figure 5).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7401
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7402
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7403
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7404
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7405
Circuit Identification Chart
System Codes Chart
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7406
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7407
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7408
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7409
Circuit Identification Chart
SYSTEM CODES CHART
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7410
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7411
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7412
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7413
Symbols
Symbols
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7414
Symbols
Symbols
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7415
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7416
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7417
Auxiliary Power Outlet: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7418
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7419
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7420
Auxiliary Power Outlet: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Diagram Information and Instructions > Page 7421
Diagram 501-12-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Page 7422
Auxiliary Power Outlet: Service and Repair
PANEL - POWER POINT
Removal and Installation
1. Disconnect the battery ground cable
2. Remove the screws and position the power point receptacle and panel aside.
3. Disconnect the power point receptacle electrical connector.
4. Remove the power point receptacle from the panel.
1. Remove the screws. 2. Remove the power point receptacle.
5. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7431
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7432
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7433
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7434
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7435
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7436
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7437
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7438
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 7444
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 7445
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 7446
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 7447
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 7448
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 7449
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 7450
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 7451
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Page 7452
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7457
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7458
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7459
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7460
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7461
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7462
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7463
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7464
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7465
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7466
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7467
Fuse: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7468
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7469
Fuse: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7470
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7471
Fuse: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7472
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions
Fuse: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7475
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7476
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7477
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7478
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7479
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7480
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7481
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7482
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7483
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7484
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7485
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7486
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7487
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7488
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7489
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7490
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7491
Fuse: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7492
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 7493
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7496
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7497
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7498
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7499
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7500
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7501
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7502
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7503
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7504
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7505
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7506
Fuse: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7507
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7508
Fuse: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7509
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7510
Fuse: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7511
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7516
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7517
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7518
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7519
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7520
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7521
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7522
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7523
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7524
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7525
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7526
Fuse Block: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7527
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7528
Fuse Block: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7529
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7530
Fuse Block: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7531
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7534
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7535
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7536
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7537
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7538
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7539
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7540
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7541
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7542
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7543
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7544
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7545
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7546
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7547
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7548
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7549
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7550
Fuse Block: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7551
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7552
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 7553
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7556
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7557
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7558
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7559
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7560
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7561
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7562
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7563
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7564
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7565
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7566
Fuse Block: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7567
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7568
Fuse Block: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7569
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7570
Fuse Block: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7571
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection > Page 7575
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection > Page 7579
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7584
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7585
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7586
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7587
Multiple Junction Connector: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7588
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7589
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7590
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7591
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7592
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7593
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7594
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7595
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7596
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7597
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7598
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7599
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7600
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110 > Page 7601
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection > Page 7606
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection > Page 7610
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7615
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7616
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7617
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7618
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7619
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7620
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7621
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7622
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7623
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7624
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7625
Relay Box: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7626
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7627
Relay Box: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7628
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7629
Relay Box: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
7630
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7633
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7634
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7635
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7636
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7637
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7638
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7639
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7640
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7641
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7642
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7643
Relay Box: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7644
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7645
Relay Box: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7646
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7647
Relay Box: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 7648
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7653
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7654
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7655
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7656
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7657
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7658
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7659
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7660
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7661
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7662
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7663
Relay Box: Locations Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7664
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7665
Relay Box: Locations Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7666
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7667
Relay Box: Locations Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7668
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Central Junction Box (CJB) - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7671
Central Junction Box (CJB) - Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7672
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7673
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7674
Fuse 17 - 36
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7675
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Sport, Before June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7676
Sport Trac, Before June 16
Sport, As Of June 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7677
Sport Trac, As Of June 16
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7678
Fuse 1 - 16
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7679
Fuse 17 - 46A
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7680
Fuse 46B - 56B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7681
Relay Box: Application and ID Auxiliary Relay Box 3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7682
Vehicle Rear End, LH Side - Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7683
Relay Box: Application and ID Auxiliary Relay Box 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7684
Engine Compartment, RH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7685
Relay Box: Application and ID Auxiliary Relay Box 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7686
Behind Dash Panel, LH Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips
Technical Service Bulletin # 05-18-7 Date: 050922
Electrical - Wiring Soldering/Crimping Service Tips
TSB 05-18-7
09/22/05
WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS
FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006
Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005
Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005
Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006
F-650, F-750 2006 Low Cab Forward
LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood
2003-2005 Aviator 2006 Mark LT
MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego
2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model
years.
ISSUE Wire harness repairs are supported through the availability of individual components such
as:
^ Wire terminals with machine crimped pigtails
^ Hard shell connectors
^ Dual wall heat shrink tubing
^ Complete, loaded, wiring pigtail kits
Some of the available tools and service parts that are helpful when performing wiring harness
repairs are:
^ Motorcraft Wiring Pigtail Catalog (see website for more information)
^ Rotunda Wire Splice Tool kit 164-R5903
^ General Wire Terminal Repair Kit (order through Ford Component Sales)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7691
Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15
web site. To access on PTS:
^ Select the year/model of the vehicle on the P15 home page
^ Select the wiring tab
^ Select the link to the pigtail or terminal repair kit at the top right of screen.
Additional service information contained in this TSB detailing wire folding, soldering, and crimping
techniques may be helpful.
ACTION
REPAIR VS REPLACEMENT
The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell
connectors when available. The only exceptions to this procedure are when:
^ The repair cost exceeds the cost to replace the wiring harness
^ There are no component parts released to service the wiring harness
RESTRAINTS RELATED WIRING REPAIRS
If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair
them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford
Motor Company publication.
If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401,
14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified
in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with
white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits
with gold plated terminals are also available in the parts catalog.
Disclaimer
Service Tips
Refer to applicable model year wiring diagrams for circuit information.
Twisted Wire Circuits
For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51
mm) Twist the repaired wires in the same direction and with the same general twist rate as the
original wiring. Reapply the shielding on shielded circuits.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7692
Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2).
Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed
(Figure 2). Silicone must not be used.
Excess wire from the harness can be folded back on itself to maintain the harness length.
Reapply any convolute and tape that was removed to make the repair.
For 16 AGW and Smaller Diameter Wire
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7693
1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2,
taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled
at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut
off the end and re-strip.
2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced.
Twist wires together. Solder wires together (Figure 4).
NOTE
USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER
FOR WIRE REPAIR.
3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond.
NOTE
WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES.
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Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7694
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7695
4. Evenly position heat shrink tubing over wire repair (Figure 5).
NOTE
OVERLAP TUBING ON BOTH WIRES.
5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt
appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the
hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between
the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the
solder point (Figure 5).
For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs)
1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs
can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire
is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during
stripping, cut off the end and re-strip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7696
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7697
NOTE
THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN
HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE
FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP
LENGTHS AND FOLDING TECHNIQUES.
2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4
mm) away from stripped end (Figure 6).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7698
3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or
equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice
(Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles
together until the ratchet releases, then allow the jaws of the tool to open fully.
4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to
place the brazed seam of the butt splice toward the indenter (Figure 8).
5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages
sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the
butt splice.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7699
6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt
splice (Figure 8).
7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool
handles to open, then remove crimped butt splice.
8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping
chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool
around.
9. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly
off center, but not off the end of the buff splice (Figure 9-a).
b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of
buff splice (Figure 9-b).
c. Wire is visible through inspection hole of splices (Figure 9-c).
10. Evenly position heat shrink tubing over wire repair (Figure 5).
NOTE
OVERLAP TUBING ON BOTH WIRES.
11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt
appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the
hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between
the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the
solder point (Figure 5).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Alignment Procedure Revision
Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision
TSB 04-24-19
12/13/04
REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT
HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS
FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer
Sport Trac
ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar
and coil spring front suspensions has been discontinued. If the caster and camber settings need to
be adjusted, a washer must now be installed.
The right hand upper control arm design changed from a two piece design to a single piece design
during the 2003 model year. The single piece design is now the only version of the upper control
arm available for service of prior model year Rangers.
ACTION Use the following Camber And Caster Adjustment procedure when either camber or
caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a
vehicle equipped with single piece upper control arm.
Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if
only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm.
SERVICE PROCEDURE
CAMBER AND CASTER ADJUSTMENT
NOTE
THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST
BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME
SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE
MOVEMENT OF THE UPPER ARM IN THE SLOT.
1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1).
2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is
tension, but the upper control arm can be moved for the alignment adjustment.
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Alignment Procedure Revision > Page 7705
3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and
rear of the upper control arm should be made equally.
4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m).
5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for
information.
CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM
1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the
ball joint forward.
2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint
rearward.
3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m).
4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for
information.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3084 07
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 7706
Alignment: Specifications
Alignment Specifications
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 7707
General Specifications
Related Torque Specifications
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 7708
Alignment: Description and Operation
WHEEL ALIGNMENT ANGLES
Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting
bolts. Toe is adjusted by the use of the front wheel spindle tie-rod.
Negative and Positive Camber
Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive
or negative and has a direct effect on tire wear.
Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when
viewed from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Positive Toe (Toe In)
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 7709
Negative Toe (Toe Out)
Toe The vehicle toe setting: ^
affects tire wear and directional stability.
^ must be checked after adding aftermarket equipment, such as a snowplow or body.
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 7710
Ride Height
Wheel Track
Wheel Track
Dogtracking
Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily
crowned roads can give the illusion of dogtracking.
Wander Wander is the tendency of the vehicle to require frequent, random left and right steering
wheel corrections to maintain a straight path down a level road.
Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the
steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually
experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes
or irregularities in the road surface.
Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with
various road surfaces and observed by the driver as small rotational oscillations of the steering
wheel.
Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor
return of the steering wheel to center after a turn or the steering correction is completed.
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 7711
Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be
overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does
with hands off the steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the
steering wheel as the wheel is rocked slowly left and right within very small turns around center or
straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center."
^
Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear
teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the
effort from the self-aligning forces at the road wheel or tire patch.
^ In the diagnosis of a readability problem, it is important to understand the difference between
wander and poor groove feel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment
Alignment: Service and Repair Camber and Caster Adjustment
Camber and Caster Adjustment
1. Remove the nuts and alignment plates.
2. Install the cams and the nuts.
3. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame
pocket to aid in moving the arm.
To increase the LF caster and camber, use the following steps. 1
To increase caster, move the front of the front suspension arm bushing joint outboard and move
the rear of the front suspension arm bushing joint inboard.
2 To increase camber, move the front suspension arm bushing joint outboard equally.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7714
4. To decrease the LF caster and camber, use the following steps.
1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move
the rear of the front suspension arm bushing joint outboard.
2 To decrease camber, move the front suspension arm bushing joint inboard equally.
5. Tighten the nuts.
6. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame
pocket to aid in moving the arm.
To increase RF caster and camber, use the following steps. 1
To increase caster, move the front of the front suspension arm bushing joint outboard and move
the rear of the front suspension arm bushing joint inboard.
2 To increase camber, move the front suspension arm bushing joint outboard equally.
7. To decrease the RF caster and camber, use the following steps.
1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move
the rear of the front suspension arm bushing joint outboard.
2 To decrease camber, move the front suspension arm bushing joint inboard equally.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7715
8. Increase the caster split.
1 Loosen the nuts.
2 Adjust the caster set bolts forward.
9. Decrease the caster split.
1 Loosen the nuts.
2 Adjust the caster set bolts rearward.
10. Tighten the nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7716
Alignment: Service and Repair Ride Height
Ride Height
1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to
normalize the vehicle static ride height.
3. Measure the distance between the center line of the front suspension lower arm bushing bolt
and the lift. Record the measurement.
4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the
measurement.
^ Take the measurement from the midpoint of the surface shown.
5. Determine ride height.
^ Subtract measurement 1 from measurement 2. This is the ride height.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7717
6. NOTE: The torsion bar adjusting bolt is coated with adhesive that wears off after disassembly. If
the torsion bar system is ever disassembled or
the torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when
re-assembling.
Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting
bolt. ^
Tighten the torsion bar adjusting bolt to increase the torque or raise the height.
^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7718
Alignment: Service and Repair Toe Adjustment
Toe Adjustment
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake
pedal.
3. Check the toe settings; follow the manufacturer's instructions.
4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is
rotated.
Remove the clamps.
5. Loosen the nuts.
^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7719
6. Rotate the front wheel spindle tie-rods.
7. Tighten the nuts.
8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications
Front Steering Knuckle: Specifications
Front Wheel Spindle Tie-Rod Ball Socket 89 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications > Page 7724
Front Steering Knuckle: Service and Repair
Special Tool(s)
Special Tool(s)
Removal
1. Remove the brake disc and hub. 2. Remove the front brake anti-lock sensor.
1 Remove the anti-lock sensor electrical wire from the clamp.
2 Remove the bolt and position the sensor aside.
3. Remove the tie-rod end castellated nut.
1 Remove the cotter pin.
2 Remove the castellated nut.
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Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications > Page 7725
4. Use the Pitman Arm Puller to separate the tie-rod end from the front wheel spindle. 5. Use a
suitable jack stand to support the front suspension lower arm.
6. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it
from tilting before removing the pinch bolt and
nut.
Remove the pinch bolt and nut from the front wheel spindle.
7. Remove the lower ball joint castellated nut.
1 Remove the lower ball joint cotter pin.
2 Remove the lower ball joint castellated nut.
8. Use the Pitman Arm Puller to remove the front wheel spindle.
Installation
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Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications > Page 7726
1. NOTE: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent
together at a right angle. Failure to do so can
cause damage to the wheel and tire assembly.
Install the lower ball joint castellated nut.
1 Position the front wheel spindle to the lower ball joint.
2 Install the lower ball joint castellated nut.
3 Install a new cotter pin.
2. Install the pinch bolt and nut.
1 Position the front wheel spindle.
2 Install the pinch bolt and nut.
3. Remove the jack from under the front suspension lower arm.
4. CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers
bent together at a right angle. Failure to do so
can cause damage to the wheel and tire assembly.
Connect the tie-rod end to the front wheel spindle.
1 Position the tie-rod end.
2 Install the tie-rod end castellated nut.
3 Install a new cotter pin.
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Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications > Page 7727
5. Install the front brake anti-lock sensor and position the anti-lock sensor electrical wire in the
clamp. 6. Install the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Purging
Special Tools
Special Tool(s)
CAUTION: If the air is not purged from the power steering system correctly, premature power
steering pump failure can result. The condition can occur on pre-delivery vehicles with evidence of
aerated fluid or on vehicles that have had steering component repairs.
1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The
power steering purge procedure must be performed
prior to any component repair for which power steering noise complaints are accompanied by
evidence of aerated fluid.
Remove the reservoir cap. Check the fluid. ^
Use MERCON Multi-Purpose(ATF) Transmission Fluid XT-2-QDX or MERCON equivalent.
2. Tightly insert the stopper of the vacuum pump into the reservoir. 3. Start the vehicle.
4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed
set at idle. 5. Release the vacuum and remove the vacuum pump.
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 7732
6. CAUTION: Do not overfill the power steering pump reservoir (3E764).
Fill the reservoir. ^
Use MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or MERCON equivalent.
7. Reinstall the vacuum pump. Apply and maintain maximum vacuum.
8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds
at a time. Damage to the power steering pump
can occur.
Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes.
9. Stop the engine, release the vacuum, and remove the vacuum pump.
10. Install the reservoir cap. 11. Check for fluid leaks at all of the connections. If the power steering
fluid shows signs of air, repeat this procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage
TSB 07-1-7
01/22/07
MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER
STEERING SYSTEMS
FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort
2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle
2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53
Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005
Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007
Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series
2000-2007 F-650, F-750 2006-2007 Low Cab Forward
LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln
LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator
2006-2007 Mark LT 2007 MKX
MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar
2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002
Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid for power steering systems originally requiring MERCON(R).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7737
ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be
serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids
labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission
Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining
inventory has been depleted.
SERVICE PROCEDURE
Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V.
CAUTION
APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER
STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY
OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Page 7738
Power Steering Fluid: Specifications /
/
Power Steering Fluid Type MERCON(R) ATF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 >
Sep > 05 > Steering - Shudder on Low Speed Turns
Power Steering Fluid Cooler: Customer Interest Steering - Shudder on Low Speed Turns
TSB 05-17-15
09/05/05
STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified through the steering system. The
condition will vary according to ambient temperature, road surface friction, and steering wheel
turning speed.
ACTION As design changes have taken place in the steering system, it is important to note the
VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service
Procedure. Perform a thorough evacuation of air from the power steering system after
replacement/installation of parts.
SERVICE PROCEDURE
NOTE
BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT
INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM
FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL,
SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE
AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT
ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE
DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN
LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut
securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE
THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA
TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF
INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 >
Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7747
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO
STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT
DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to the Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 >
Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7748
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 >
Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7749
3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack
cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop
Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering
Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The
Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace
The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S
System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A,
3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And
Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A,
3504A9, 3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And
Purge The P/S System (Do Not
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 >
Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7750
Use With 3504A, 3504A9, 3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 >
Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped
Power Steering Fluid Cooler: Customer Interest Steering - Shudder on Low Speed Turns or When
Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 >
Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7755
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 >
Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7756
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 >
Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7757
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 >
Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7758
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 >
Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7759
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 >
Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7760
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns
Power Steering Fluid Cooler: All Technical Service Bulletins Steering - Shudder on Low Speed
Turns
TSB 05-17-15
09/05/05
STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified through the steering system. The
condition will vary according to ambient temperature, road surface friction, and steering wheel
turning speed.
ACTION As design changes have taken place in the steering system, it is important to note the
VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service
Procedure. Perform a thorough evacuation of air from the power steering system after
replacement/installation of parts.
SERVICE PROCEDURE
NOTE
BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT
INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM
FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL,
SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE
AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT
ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE
DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN
LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut
securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE
THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA
TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF
INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7766
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO
STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT
DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to the Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7767
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7768
3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack
cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop
Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering
Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The
Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace
The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S
System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A,
3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And
Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A,
3504A9, 3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And
Purge The P/S System (Do Not
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7769
Use With 3504A, 3504A9, 3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped
Power Steering Fluid Cooler: All Technical Service Bulletins Steering - Shudder on Low Speed
Turns or When Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7774
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
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03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7775
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7776
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7777
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7778
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7779
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Page 7780
Power Steering Fluid Cooler: Specifications
Power steering fluid cooler nuts 59 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Page 7781
Power Steering Fluid Cooler: Service and Repair
Removal and Installation
1. Raise and support the vehicle.
2. Disconnect the power steering return hose at the power steering fluid cooler.
^ Drain the fluid into a suitable container.
3. Remove the power steering fluid cooler to crossmember nuts.
4. Disconnect the power steering return line hose. Remove the power steering fluid cooler. 5. To
install, reverse the removal procedure.
^ Fill, purge and leak check the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications
Power Steering Line/Hose: Specifications
Steering line to gear clamp plate nut 18 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications > Page 7785
Power Steering Line/Hose: Service and Repair
Hose
Special Tools
Special Tool(s)
Removal and Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications > Page 7786
1. Refer to the System View illustration for the hose routing and retention points.
2. When connecting a fitting with a seal ring, a new seal ring must be installed.
^ The special tool is used to install the return line connector seal and the pressure line connector
seal.
3. Fill, purge and leak check the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns
Power Steering Pressure Control Valve: Customer Interest Steering - Shudder on Low Speed
Turns
TSB 05-17-15
09/05/05
STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified through the steering system. The
condition will vary according to ambient temperature, road surface friction, and steering wheel
turning speed.
ACTION As design changes have taken place in the steering system, it is important to note the
VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service
Procedure. Perform a thorough evacuation of air from the power steering system after
replacement/installation of parts.
SERVICE PROCEDURE
NOTE
BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT
INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM
FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL,
SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE
AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT
ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE
DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN
LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut
securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE
THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA
TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF
INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7795
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO
STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT
DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to the Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7796
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7797
3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack
cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop
Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering
Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The
Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace
The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S
System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A,
3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And
Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A,
3504A9, 3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And
Purge The P/S System (Do Not
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7798
Use With 3504A, 3504A9, 3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped
Power Steering Pressure Control Valve: Customer Interest Steering - Shudder on Low Speed
Turns or When Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7803
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7804
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7805
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7806
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7807
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: >
03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7808
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns
Power Steering Pressure Control Valve: All Technical Service Bulletins Steering - Shudder on Low
Speed Turns
TSB 05-17-15
09/05/05
STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified through the steering system. The
condition will vary according to ambient temperature, road surface friction, and steering wheel
turning speed.
ACTION As design changes have taken place in the steering system, it is important to note the
VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service
Procedure. Perform a thorough evacuation of air from the power steering system after
replacement/installation of parts.
SERVICE PROCEDURE
NOTE
BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT
INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM
FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL,
SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE
AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT
ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE
DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN
LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut
securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE
THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA
TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF
INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7814
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO
STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT
DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to the Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7815
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7816
3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack
cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop
Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering
Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The
Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace
The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S
System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A,
3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And
Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A,
3504A9, 3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And
Purge The P/S System (Do Not
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7817
Use With 3504A, 3504A9, 3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped
Power Steering Pressure Control Valve: All Technical Service Bulletins Steering - Shudder on Low
Speed Turns or When Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7822
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
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Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7823
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7824
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7825
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7826
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure
Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7827
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns
Power Steering Pump: Customer Interest Steering - Shudder on Low Speed Turns
TSB 05-17-15
09/05/05
STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified through the steering system. The
condition will vary according to ambient temperature, road surface friction, and steering wheel
turning speed.
ACTION As design changes have taken place in the steering system, it is important to note the
VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service
Procedure. Perform a thorough evacuation of air from the power steering system after
replacement/installation of parts.
SERVICE PROCEDURE
NOTE
BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT
INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM
FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL,
SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE
AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT
ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE
DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN
LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut
securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE
THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA
TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF
INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7836
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO
STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT
DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to the Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7837
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7838
3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack
cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop
Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering
Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The
Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace
The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S
System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A,
3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And
Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A,
3504A9, 3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And
Purge The P/S System (Do Not
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7839
Use With 3504A, 3504A9, 3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped
Power Steering Pump: Customer Interest Steering - Shudder on Low Speed Turns or When
Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7844
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7845
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7846
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7847
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7848
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7849
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05
> Steering - Shudder on Low Speed Turns
Power Steering Pump: All Technical Service Bulletins Steering - Shudder on Low Speed Turns
TSB 05-17-15
09/05/05
STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified through the steering system. The
condition will vary according to ambient temperature, road surface friction, and steering wheel
turning speed.
ACTION As design changes have taken place in the steering system, it is important to note the
VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service
Procedure. Perform a thorough evacuation of air from the power steering system after
replacement/installation of parts.
SERVICE PROCEDURE
NOTE
BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT
INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM
FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL,
SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE
AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT
ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE
DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN
LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut
securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE
THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA
TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF
INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05
> Steering - Shudder on Low Speed Turns > Page 7855
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO
STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT
DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer
to the Workshop Manual, Section 211-02.
2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing
cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach
a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the new return line from the new cooler and connect the new cooler fin pack to the existing return
line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for
complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05
> Steering - Shudder on Low Speed Turns > Page 7856
4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole
check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section
211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release
B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05
> Steering - Shudder on Low Speed Turns > Page 7857
3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack
cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop
Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering
Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The
Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace
The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S
System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A,
3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And
Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A,
3504A9, 3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And
Purge The P/S System (Do Not
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05
> Steering - Shudder on Low Speed Turns > Page 7858
Use With 3504A, 3504A9, 3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped
Power Steering Pump: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or
When Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7863
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7864
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7865
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7866
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7867
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7868
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Power Steering Pump Pulley
Power Steering Pump: Specifications
Power steering pump pulley bolts 18 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Power Steering Pump Pulley > Page 7871
Power Steering Pump: Specifications
Type C111
Flow rate 2.2-2.6 gal/min
@ 74 degrees-80 degrees C (165 degrees-175 degrees F) and
engine speed set at 1500 rpm
Maximum Pressure 150 psi
@ 74 degrees-80 degrees C ( 165 degrees- 175 degrees F) and
engine speed set at 1500 rpm
Minium Flow rate 1.15 gal/min
@ 74 degrees-80 degrees C (165 degrees-175 degrees F) power
steering analyzer set at 5,102kpa (750 psi) and engine speed
set at idle
Relief pressure 1300-1480 psi
Power steering pressure hose to power steering pump 48 ft.lb
Power steering pump bolts 18 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 7872
Power Steering Pump: Application and ID
Power Steering Pump
Power Steering Pump
Pump Identification
CAUTION: Always use the ID code when ordering service parts.
The pump identification code is located on a tag attached to the power steering pump.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump
Power Steering Pump: Service and Repair Power Steering Pump
Special Tools
Special Tool(s)
Removal 1. Remove the engine cooling fan.
2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt.
4. Remove the power steering pump pulley.
1 Remove the bolts.
2 Remove the power steering pump pulley.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7875
5. Disconnect the power steering return line hose at the power steering fluid reservoir.
^ Allow the system to drain.
6. Disconnect the power steering pressure hose from the power steering pump.
7. Disconnect the power steering fluid reservoir outlet hose from the power steering pump.
1 Compress and move the power steering fluid reservoir outlet hose clamp.
2 Disconnect the power steering fluid reservoir outlet hose from the power steering pump.
8. Remove the power steering pump.
1 Remove the bolts.
2 Remove the power steering pump.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7876
1. Install the power steering pump.
1 Position the power steering pump.
2 Install the bolts.
2. Connect the power steering fluid reservoir outlet hose to the power steering pump.
1 Connect the power steering fluid reservoir outlet hose to the power steering pump.
2 Compress and move the power steering fluid reservoir outlet hose clamp into place.
3. Using the special tool, install a new seal on the power steering pressure hose.
4. Connect the power steering pressure hose to the power steering pump.
5. Connect the power steering return line hose to the power steering fluid reservoir. 6. Install the
power steering pump pulley.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7877
1 Position the power steering pump pulley.
2 Install the bolts.
7. Install the drive belt.
8. Tighten the power steering pump pulley bolts. 9. Install the engine cooling fan.
10. Fill, purge and leak check the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7878
Power Steering Pump: Service and Repair Power Steering Pump Pulley
Removal and Installation
1. Remove the engine cooling fan.
2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt.
4. Remove the power steering pump pulley.
1 Remove the bolts.
2 Remove the power steering pump pulley.
5. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped
Power Steering Valve: Customer Interest Steering - Shudder on Low Speed Turns or When
Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7887
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7888
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7889
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7890
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7891
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7892
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped
Power Steering Valve: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or
When Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7898
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7899
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7900
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7901
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7902
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03
> Steering - Shudder on Low Speed Turns or When Stopped > Page 7903
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Seats Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Disconnect the battery ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical
connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air
bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor
connector.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side floor connector. 11. Reconnect the battery ground cable.
Seats Not Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery
ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7909
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate
controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint
system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector
to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector
beneath the front seat.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
passenger side air bag electrical connector beneath
the front seat.
11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat.
12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side air bag electrical connector beneath the
front seat.
13. Reconnect the battery ground cable.
Deactivation Procedure
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will This will
reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7910
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood connected.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7911
8. Remove the driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
11. Open the glove compartment door past its stops to access the mounting screws.
12. Remove the two screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7912
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door. Reaching one hand into the glove
compartment opening push out on the passenger air bag module and separate it from the
instrument panel. Note the wire harness routing for installation.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
Vehicles without seat side air bags
16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag
bridge resistor from the side air bag to floor connector.
If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints
control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor
connector, a low resistance fault will be generated by the RCM.
Vehicles with seat side air bags and power driver seat
17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the battery ground
cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Vehicles with seat side air bags
18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side
air bags and power driver seat
19. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery
ground cable (14301) and wait at least one minute. For additional information, See: Starting and
Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7913
Vehicles with seat side air bags
20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
All vehicles
24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close
the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery
Reactivation Procedure
Reactivation
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7914
1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the
instrument panel, open the kick panel cover and remove the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the wiring Diagram Manual.
3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
Vehicles with seat side air bags
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
Vehicles with seat side air bags and power driver seat
8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7915
Vehicles with seat side air bags
9. Position the front seats rearward.
Vehicles with seat side air bags and power driver seat
10. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air
bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply
energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery
All vehicles
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical
connector.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Position the passenger air bag module into the instrument panel. Route the wire harness as noted
in removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7916
14. Install the two screws.
15. Close the glove compartment door.
16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
17. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to
the steering wheel.
18. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7917
19. Install the two steering wheel back cover plugs.
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear
blower, 15A with rear blower) to the CJB and close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to
OFF. Wait 10 seconds, then turn the key back to
ON and visually monitor the air bag indicator with the air bag modules installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an air bag
supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light.
-remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after
the ignition switch has been turned from the OFF to the ON position. This is the time required for
the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is
inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this
occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
25. Clear all continuous DTCs from the restraints control module using a scan tool.
Procedures For Repair Operations
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7918
accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7919
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7920
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7921
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7922
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Seats Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic
tool from the driver seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger
seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic
tool from the clockspring connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7923
8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable.
10. Prove out the system.
Seats Not Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring
connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove
the restraint system diagnostic tool from the floor connector beneath the front passenger seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the
passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from
the floor connector beneath the driver seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver
seat.
10. Reconnect the battery ground cable. 11. Prove out the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7924
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 7925
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint
System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Functional Lock Cylinder
Steering Column Lock: Service and Repair Functional Lock Cylinder
Ignition Switch Lock Cylinder-Functional Lock Cylinder
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
3. To install, reverse the removal procedure.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Functional Lock Cylinder > Page 7930
Steering Column Lock: Service and Repair Non-Functional Lock Cylinder
Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder
Removal and Installation
1. NOTE: Make sure the front wheels are in the straight-ahead position.
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and
instructions in the steering wheel
removal and installation procedure.
Remove the steering wheel assembly.
3. Twist off the cap from the ignition switch cylinder.
4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock
repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to
build the new lock cylinder to the current key code of the vehicle.
Remove the ignition switch lock cylinder. ^
Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch
lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the
steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Functional Lock Cylinder > Page 7931
5. Remove the bearing retainer.
6. Remove the bearing and gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
7. To install, reverse the removal procedure.
^ Install a new ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
Steering Gear: Specifications
Steering gear turns (stop-to-stop) 4.0 : 1
Steering gear to crossmember stud bolts and nuts (E coated frame) 111 ft.lb
Steering gear to crossmember stud bolts and nuts (wax-coated frame) 148 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7935
Steering Gear: Diagrams
Steering Gear Mounting
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7936
Steering Gear
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7937
Steering Gear: Application and ID
Steering Gear Identification
Explorer Sport
Explorer Sport Trac
CAUTION: Always use the ID code when ordering service parts.
The steering gear identification code is located on a tag attached to the steering gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7938
Steering Gear: Service and Repair
Special Tool(s)
Removal
1. Place front wheels in the straight ahead position. Do not lock the steering column. 2. Remove
the front wheel and tire assemblies.
3. Remove the radiator air deflector.
1 Remove the bolts.
2 Remove the radiator air deflector.
4. Remove the power steering cooler.
5. Loosen the LH tie-rod end jam nut.
6. Remove the cotter pins and the castellated nuts.
^ Discard the cotter pins.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7939
7. CAUTION: Do not damage the tie-rod end dust boot when installing the special tool.
NOTE: Remove the adapter from the ball end of the special tool. Apply a small amount of grease to
the tie-rod end stud and the ball of the special tool.
Using the special tool, separate the tie-rod ends from the knuckles.
8. Remove the LH tie-rod end.
^ Count and record the number of turns required to remove the tie-rod end.
9. Remove the front stabilizer bar.
^ Mark the driver side end of the stabilizer bar for correct installation.
10. Rotate the steering column shaft to access the intermediate shaft pinch bolt. Remove the pinch
bolt. 11. Lower the vehicle. 12. Turn the steering wheel back to the straight ahead position. Turn
the ignition key to the locked position. 13. Raise the vehicle.
14. CAUTION: Do not allow the steering column intermediate shaft to rotate while the shaft is
disconnected from the steering gear or damage to the
clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be
removed and recentered.
Disconnect the intermediate shaft from the steering gear input shaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7940
15. Remove the nut and disconnect the power steering lines.
^ Drain the fluid into a suitable container.
^ Install new O-ring seals.
16. Plug the ends of the fluid lines and ports in the steering gear to prevent damage and entry of
dirt.
17. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the
steering gear fluid transfer tubes.
Remove the nuts.
18. Remove the stud bolts and washers.
19. Remove the steering gear to crossmember insulator bushings.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7941
20. Rotate the steering gear control valve housing toward the front of the vehicle. 21. Turn the
steering gear input shaft to the right until the stop is reached.
22. Move the steering gear as far to the RH side of the vehicle as possible.
23. Move the LH front wheel spindle tie-rod forward to clear the frame crossmember.
24. Remove the steering gear from the vehicle.
Installation
All vehicles
1. NOTE: Make sure the steering gear input shaft is turned to the left until the stop is reached.
NOTE: Handle the steering gear with caution to avoid damage to the fluid transfer tubes and to
avoid dimples in the tie-rod boots.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7942
Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns.
2. NOTE: Make sure the steering gear control valve housing is turned toward the front of the
vehicle.
Install the steering gear into the RH opening of the crossmember.
3. Move the steering gear as far to the RH side of the vehicle as possible.
4. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the
steering gear into position. 5. To place the steering gear in the straight ahead position, turn the
steering gear input shaft to the left by half the number of turns recorded
previously.
6. Rotate the steering gear control valve housing toward the rear of the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7943
7. Install the steering gear to crossmember insulator bushings as shown.
^ The large end of the metal sleeve must be positioned downward.
^ Check that the mounting surfaces on the crossmember are clean and free of foreign material.
8. Install the steering gear to crossmember washers and stud bolts.
^ The dished side of the washers face down.
Vehicles with E-coated frame
9. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the
steering gear fluid transfer tubes.
NOTE: The steering gear mounting bolts and nuts will have two different tightening specifications
based upon the type of frame coating that is used. The E-coated frame is black and very smooth.
The wax-coated frame is gray and very sticky.
Install the nuts.
Vehicles with wax-coated frame
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7944
10. Install the nuts.
All vehicles
11. Install the lines and clamp plate.
12. CAUTION: Do not allow the steering column intermediate shaft to rotate while the shaft is
disconnected from the steering gear or damage to the
clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be
removed and recentered.
Connect the intermediate shaft to the steering gear input shaft. Install the pinch bolt.
13. Install the power steering fluid cooler. 14. Install the front stabilizer bar.
^ Orientate the front stabilizer bar as noted during removal.
15. Install the LH tie-rod end on the front wheel spindle tie-rod.
^ Rotate the tie-rod end the number of turns recorded during removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7945
16. Connect the tie-rod ends to the steering knuckles.
1 Position the tie-rod ends on the steering knuckles.
2 Install the castellated nuts.
3 Install the new cotter pins. ^
Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot
seals.
17. Tighten the tie-rod jam nuts.
18. Install the radiator air deflector.
1 Position the radiator air deflector.
2 Install the bolts.
19. Install the front wheel and tire assemblies. 20. Prove out the Supplemental Restraint System
(SRS). 21. Fill, purge and leak check the power steering system. 22. Check the wheel alignment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications
Steering Shaft: Specifications
Lower intermediate shaft pinch bolt 36 ft.lb
Intermediate shaft to lower intermediate shaft bolt 30-40 ft.lb
Upper intermediate shaft to steering column bolt 19-25 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering
Wheel Is Loose
Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose
TSB 07-4-3
03/05/07
LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE
FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007
Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty
2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport
2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape
Hybrid 2007 Edge 2004-2007 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007
MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX
MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan
2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid
This article supersedes TSB 04-24-3 to update the vehicle model years.
ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather
coming loose from the spoke area.
ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke.
Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT
STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY
WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL.
CAUTION
AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering
Wheel Is Loose > Page 7957
1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING
WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B.
2. Fold loose leather out of the way.
3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke.
4. Fold the leather back into its original position.
5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to
the wheel spoke (apply pressure for at least 30 seconds).
NOTE
THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE
REPAIR AREA.
6. Reinstall steering wheel.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT070403 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time.
DEALER CODING
CONDITION
BASIC PART NO. CODE
3600 33
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On
Steering Wheel Is Loose
Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is
Loose
TSB 07-4-3
03/05/07
LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE
FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007
Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty
2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport
2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape
Hybrid 2007 Edge 2004-2007 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007
MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX
MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan
2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid
This article supersedes TSB 04-24-3 to update the vehicle model years.
ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather
coming loose from the spoke area.
ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke.
Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT
STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY
WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL.
CAUTION
AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On
Steering Wheel Is Loose > Page 7963
1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING
WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B.
2. Fold loose leather out of the way.
3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke.
4. Fold the leather back into its original position.
5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to
the wheel spoke (apply pressure for at least 30 seconds).
NOTE
THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE
REPAIR AREA.
6. Reinstall steering wheel.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT070403 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time.
DEALER CODING
CONDITION
BASIC PART NO. CODE
3600 33
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7964
Steering Wheel: Specifications
Steering wheel turning 10 ft.lb
Steering wheel rotation sensor bolts 10 ft.lb
Steering wheel bolt 25-34 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7965
Steering Wheel: Service Precautions
WARNINGS:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generate combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged trim covers must be installed new, not repainted.
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components, whether or not the air bag is
deployed.
- The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior
to road use. Failure to remove could result in injury and possible violation of vehicle safety
standards.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7966
Steering Wheel: Service and Repair
Special Tool(s)
WARNINGS:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generate combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged trim covers must be installed new, not repainted.
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components, whether or not the air bag is
deployed.
- The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior
to road use. Failure to remove could result in injury and possible violation of vehicle safety
standards.
Removal
NOTE: Make sure the wheels are in the straight-ahead position.
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7967
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery cable and wait at least one minute.
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
4. Remove the bolts and the lower steering column opening finish panel reinforcement.
5. Disconnect the air bag sliding contact electrical connector at the base of the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7968
6. Attach the restraint system diagnostic tool to the vehicle harness side of the air bag sliding
contact electrical connector at the base of the steering
column.
7. Connect the battery ground cable. 8. With the restraint system diagnostic tool connected to the
vehicle harness side of the air bag sliding contact at the base of the steering column,
prove out the air bag system
9. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag
sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy,
disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary
batteries and power supplies (if equipped).
Disconnect the battery cable and wait at least one minute.
10. Remove the two steering wheel back cover plugs.
11. Remove the two driver air bag module retaining bolts. 12. Remove the driver air bag module.
^ Disconnect the driver air bag module electrical connector.
^ Remove the driver air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7969
13. Disconnect the steering wheel accessory electrical connector.
14. Remove and discard the steering wheel bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7970
15. CAUTION: Removing the steering wheel without using a puller can damage the column
bearings.
Use the 2-Jaw Puller or Steering Wheel Puller, as appropriate, to remove the steering wheel.
16. Remove the steering wheel while routing the wires from the air bag sliding contact through the
steering wheel.
Installation
1. Position the steering wheel while routing the wires from the air bag sliding contact through the
steering wheel.
2. Install a new steering wheel bolt.
3. Connect the steering wheel accessory electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7971
4. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Remove the restraint system diagnostic tool from the vehicle harness side of the air bag sliding
contact electrical connector at the base of the steering column.
5. Connect the air bag sliding contact electrical connector at the base of the steering column.
6. Connect the restraint system diagnostic tool to the air bag sliding contact electrical connector at
the top of the steering column. 7. Connect the battery ground cable. 8. With the restraint system
diagnostic tool connected to the air bag sliding contact electrical connector at the top of the
steering column, prove out
the air bag system.
9. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag
sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy,
disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary
batteries and power supplies (if equipped).
Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7972
10. Remove the restraint system diagnostic tool from the air bag sliding contact electrical connector
at the top of the steering column.
11. Position the driver airbag module to the steering wheel.
1 Connect the driver air bag module electrical connector.
2 Position the driver air bag module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
13. Install the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7973
14. Position the lower steering column opening finish panel reinforcement and install the bolts.
15. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
16. Position the hood release handle and install the screws. 17. Connect the battery ground cable.
18. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
With the restraint system diagnostic tool removed, prove out the air bag system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Specifications
Tie Rod End: Specifications
Tie-rod end nut 44-59 ft.lb
Tie-rod end to spindle castellated nuts 66 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid
Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid
Front Lower Ball Joint
Measurement
..................................................................................................................................................
Between lower control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.032 in (0-0.8mm)
Reference Diagram .............................................................................................................................
............................................................................. A
Front Upper Ball Joint
Measurement
..................................................................................................................................................
Between upper control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.008 in (0-0.2mm)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 7983
Reference Diagram .............................................................................................................................
............................................................................. C
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 7984
Ball Joint: Specifications
Lower Ball joint Radial Play 1/32 inch
Front Suspension arm lower ball joint nut 83-112 ft. lbs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 7985
Ball Joint: Specifications
Upper ball joint radial play - maximum 1/32 inch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Front Suspension Balljoint Inspection Job Aid
Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid
Front Lower Ball Joint
Measurement
..................................................................................................................................................
Between lower control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.032 in (0-0.8mm)
Reference Diagram .............................................................................................................................
............................................................................. A
Front Upper Ball Joint
Measurement
..................................................................................................................................................
Between upper control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.008 in (0-0.2mm)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7988
Reference Diagram .............................................................................................................................
............................................................................. C
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7989
Ball Joint: Testing and Inspection Ball Joint, Lower
Ball Joint Inspection
1. Raise and support the vehicle. 2. Prior to carrying out any inspection of the ball joints, inspect
the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be
tested.
4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement
between the lower spindle arm and the front suspension
lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged
lower ball joint. Install a new ball joint as necessary.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7990
Ball Joint: Testing and Inspection Ball Joint, Upper
Ball Joint Inspection
1. Raise and support the vehicle. 2. Prior to carrying out any inspection of the ball joints, inspect
the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be
tested.
5. While an assistant pulls and pushes the top of the tire, observe the relative movement between
the upper spindle arm and the front suspension
upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper
ball joint or loose pinch bolt joint. Tighten pinch bolt and nut as necessary. Install a new upper ball
joint as necessary.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7991
Ball Joint: Service and Repair
Ball Joint-Lower
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel and tire assembly.
3. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide
a suitable support.
Remove the caliper support bracket bolts, then position the caliper and support bracket aside.
4. Disconnect the front anti-lock brake sensor (ABS) wire from the vehicle frame.
1. Disconnect the ABS electrical connector. 2. Unclip the front ABS wire from the vehicle frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7992
5. Using a suitable jack, support the front suspension lower arm.
6. Remove the tie-rod end castellated nut.
^ Remove and discard the cotter pin and the castellated nut.
7. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to
the wheel knuckle will result.
CAUTION: Do not damage the tie-rod boot when installing the special tool.
Using the special tool, separate the tie-rod end from the front wheel knuckle.
8. Remove the lower ball joint castellated nut.
1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7993
9. Using the special tool, separate the front wheel knuckle from the front suspension lower arm.
Then, loosely install the lower ball joint castellated
nut.
10. Remove the pinch bolt and nut.
11. Remove the hand-tightened lower ball joint castellated nut, then remove the front wheel
knuckle.
12. Remove the snap ring from the ball joint. Discard the snap ring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7994
13. Using a suitable ball joint remover tool, remove the ball joint.
14. CAUTION: Do not damage the ball joint boot when installing the special tool.
NOTE: Clean and inspect the control arm ball joint bore for damage before installing a new ball
joint.
NOTE: Make sure the new ball joint snap ring is fully seated.
To install, reverse the removal procedure. ^
Always install new castellated nuts and cotter pins.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information >
Specifications
Control Arm: Specifications
Suspension upper arm cam nuts Front 98 ft.lb
Upper Control arm to frame mounting bolts and nuts 83-113 ft.lb
Lower Control arm to frame mounting bolts and nuts 140 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Lower
Control Arm: Service and Repair Lower
Special Tool(s)
Special Tool(s)
Removal
1. Remove the wheel and tire assembly.
2. Remove the stabilizer link nut, washer and bushing.
3. Remove the front shock absorber-to-front suspension lower arm nuts. 4. Remove the torsion bar.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Lower > Page 8000
5. Remove the lower ball joint castellated nut.
1 Remove the lower ball joint cotter pin.
2 Remove the lower ball joint castellated nut.
6. Use the Pitman Arm Puller to separate the front suspension lower arm from the front wheel
knuckle/spindle.
7. Remove the front suspension lower arm.
1 Remove the front suspension lower arm bolts and nuts.
2 Remove the front suspension lower arm.
Installation
All vehicles 1. NOTE: Tighten the front suspension lower arm pivot bolts and nuts until snug. Do
not tighten to specification until the installation procedure is
complete.
NOTE: Inspect the front suspension lower arm ball joints and boot seals for damage.
Install the front suspension lower arm. 1
Position the front suspension lower arm to the front suspension crossmember.
2 Install the pivot bolts and nuts and tighten until snug.
2. CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers
bent together at a right angle. Failure to do so
will cause damage to the wheel and tire assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Lower > Page 8001
Connect the front suspension lower arm to the front wheel knuckle/spindle. 1
Position the lower ball joint into the front wheel knuckle/spindle.
2 Install the new castellated nut.
3 Install a new cotter pin.
3. Install the front shock absorber-to-front suspension lower arm nuts.
4. Install the stabilizer link bushing, washer, and nut.
5. NOTE: Whenever the torsion bar or torsion bar adjuster is removed, the vehicle ride height must
be checked.
Install the torsion bar.
6. Install the tire and wheel assembly.
Vehicles with E-coated frame
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Lower > Page 8002
7. NOTE: The lower arm inboard mounting bolts and nuts will have two different specifications
based upon the type of frame coating that is used.
The E-coated fume is black and very smooth. The wax-coated frame is gray and very sticky.
Tighten the lower arm nuts.
Vehicles with wax-coated frame 8. Tighten lower arm nuts.
All vehicles 9. Inspect and adjust the front end alignment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Lower > Page 8003
Control Arm: Service and Repair Upper
Removal
1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Use a suitable jack
stand to support the front suspension lower arm.
4. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it
from tilting before removing the pinch bolt and
nut.
Remove the pinch bolt and nut from the front wheel spindle.
5. Remove the front suspension upper arm.
1 Remove the two nuts.
2 Remove the two bolts.
3 Remove the front suspension upper arm.
Installation
1. Install the front suspension upper arm.
1 Position the front suspension upper arm.
2 Install the two bolts and two nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Lower > Page 8004
2. Install the pinch bolt and nut to the front wheel spindle.
1 Position the front wheel spindle.
2 Install the pinch bolt and nut.
3. Remove the jack stand from under the front suspension lower arm. 4. Install the tire and wheel
assembly.
5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Lower the vehicle.
6. Inspect the front end ride height. 7. Inspect and adjust the front end alignment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications
Front Steering Knuckle: Specifications
Front Wheel Spindle Tie-Rod Ball Socket 89 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications > Page 8008
Front Steering Knuckle: Service and Repair
Special Tool(s)
Special Tool(s)
Removal
1. Remove the brake disc and hub. 2. Remove the front brake anti-lock sensor.
1 Remove the anti-lock sensor electrical wire from the clamp.
2 Remove the bolt and position the sensor aside.
3. Remove the tie-rod end castellated nut.
1 Remove the cotter pin.
2 Remove the castellated nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications > Page 8009
4. Use the Pitman Arm Puller to separate the tie-rod end from the front wheel spindle. 5. Use a
suitable jack stand to support the front suspension lower arm.
6. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it
from tilting before removing the pinch bolt and
nut.
Remove the pinch bolt and nut from the front wheel spindle.
7. Remove the lower ball joint castellated nut.
1 Remove the lower ball joint cotter pin.
2 Remove the lower ball joint castellated nut.
8. Use the Pitman Arm Puller to remove the front wheel spindle.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications > Page 8010
1. NOTE: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent
together at a right angle. Failure to do so can
cause damage to the wheel and tire assembly.
Install the lower ball joint castellated nut.
1 Position the front wheel spindle to the lower ball joint.
2 Install the lower ball joint castellated nut.
3 Install a new cotter pin.
2. Install the pinch bolt and nut.
1 Position the front wheel spindle.
2 Install the pinch bolt and nut.
3. Remove the jack from under the front suspension lower arm.
4. CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers
bent together at a right angle. Failure to do so
can cause damage to the wheel and tire assembly.
Connect the tie-rod end to the front wheel spindle.
1 Position the tie-rod end.
2 Install the tie-rod end castellated nut.
3 Install a new cotter pin.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications > Page 8011
5. Install the front brake anti-lock sensor and position the anti-lock sensor electrical wire in the
clamp. 6. Install the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information
> Specifications
Stabilizer Bar: Specifications
Stabilizer bar mounting bracket nuts Rear 30-40 ft.lb
Stabilizer bar-to-link nut 50-68 ft.lb
Stabilizer bar to frame mounting bolts and nuts Front 25-34 ft.lb
Stabilizer bar link to lower control arm mounting nut 15-21 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information
> Service and Repair > Front
Stabilizer Bar: Service and Repair Front
Removal
1. Raise the vehicle on a hoist. 2. Remove the front stabilizer bar links.
1 Remove the front stabilizer bar link nut.
2 Remove the front stabilizer bar link bolt.
3 Remove the front stabilizer bar spacer.
3. Remove the front stabilizer bar.
1 Remove the four (two each side) stabilizer bar bracket bolts.
2 Remove the stabilizer bar.
Installation
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information
> Service and Repair > Front > Page 8017
1. NOTE: In the event the self-tapping bolts cannot be installed in the frame, there is a kit available
with flag nuts. Consult your parts department
for further information.
To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information
> Service and Repair > Front > Page 8018
Stabilizer Bar: Service and Repair Rear
Removal and Installation
1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly.
3. Remove the nuts, bolts, brackets and the rear stabilizer bar. 4. To install, reverse the removal
procedure.
^ Use new fasteners.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Specifications
Suspension Spring ( Coil / Leaf ): Specifications
Spring Shackle Lower Bolt and Nut Rear 85 ft.lb
Spring to front frame Bracket and nut (E-coated frame) 85 ft.lb
Spring to front frame bracket bolt and nut (wax-coated frame) 111 ft.lb
Spring U-bolt nut 76 ft.lb
Jounce Bumper nut 15-21 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Specifications > Page 8022
Suspension Spring ( Coil / Leaf ): Service and Repair
Spring Tools
Special Tool(s)
Removal and Installation
All vehicles 1. Remove the wheel and tire assembly.
2. Use the High-Lift Jack to support the rear axle. 3. Separate the rear spring from the rear axle.
1 Remove the nuts.
2 Remove the U-bolts.
3 Position the rear spring plate aside.
Vehicles with E-coated frame
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Specifications > Page 8023
4. NOTE: The leaf spring forward mounting bolt will have two different tightening specifications
based upon the type of frame coating that is used.
The E-coated frame is black and very smooth. The wax-coated frame is gray and very sticky.
Remove the bolts, nuts and the rear spring.
Vehicles with wax-coated frame
5. Remove the nuts, bolts and the rear spring.
All vehicles 6. To install, reverse the removal procedure.
^ Use new fasteners.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications
Suspension Strut / Shock Absorber: Specifications
Shock absorber-to-frame nuts Front 17 ft.lb
Shock absorber lower bolt 46 ft.lb
Shock to frame mounting nut 30-41 ft.lb
Shock absorber to lower arm nuts 15-21 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
Torsion Bar: Specifications
Torsion bar cover plate bolts 35-46 ft.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
> Page 8030
Torsion Bar: Service and Repair
Special Tool(s)
Removal
1. Raise the vehicle on a hoist.
2. Remove the torsion bar cover plate.
1 Remove the torsion bar cover plate bolts.
2 Remove the torsion bar cover plate.
3. NOTE: Before relieving the torsion bar tension, measure and record the measurement of the
torsion bar adjustment bolt. This measurement will
be used as the preset depth for the new torsion bar adjustment bolt during installation.
Make preliminary adjustment references. ^
Measure and record the length where indicated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
> Page 8031
4. Relieve the torsion bar tension.
1 Position the Torsion Bar Tool and adapters.
2 Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off the adjustment bolt.
5. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive. A new bolt must be
installed if it is backed off or removed. Failure to do
so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment.
Remove the torsion bar adjustment bolt and nut.
6. Loosen the Torsion Bar Tool until the tension is removed from the torsion bar.
7. Remove the torsion bar.
1 Mark the torsion bar and the adjuster for correct installation.
2 Remove the torsion bar insulator.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
> Page 8032
3 Grasp the torsion bar, and pull it free from the front suspension lower arm.
Installation
1. Position the torsion bar and the torsion bar adjuster.
2. Install the torsion bar adjuster.
1 Align the marks on the torsion bar and the torsion bar adjuster, then install the torsion bar
adjuster.
2 Position the torsion bar insulator.
3. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive. A new bolt must be
installed if it is backed off or removed. Failure to do
so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment.
Preload the torsion bar. 1
Install the Torsion Bar Tool and the adapters.
2 Tighten the Torsion Bar Tool until the new adjustment bolt and nut can be installed.
3 Turn the adjustment bolt until the preliminary adjustment measurement (recorded length of the
old adjustment bolt) is reached.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
> Page 8033
4. Install the torsion bar cover plate.
1 Position the torsion bar cover plate.
2 Install the torsion bar cover plate bolts.
5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Lower the vehicle.
6. Adjust the ride height. 7. Check the alignment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications
- Lubricate the new rear wheel bearing. ^
For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
- Lubricate the lip of the new wheel bearing oil seal. ^
Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications > Page 8037
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of
the following actions.
^ On 4x2 vehicles, adjust the front wheel bearings.
^ On 4x4 vehicles, install a new wheel hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Ford
Wheel Bearing: Service and Repair Ford
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Special Tools
Special Tool(s)
Removal
1. Remove the axle shaft.
2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with
foreign material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.
Installation
1. Lubricate the new rear wheel bearing.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Ford > Page 8040
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Special Tool(s)
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Ford > Page 8041
NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
- Tighten the spindle nut while rotating the brake disc and hub.
- Loosen the spindle nut.
- Tighten the spindle nut while rotating the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: ^
DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE
GROUND COULD CAUSE THE VEHICLE TO MOVE.
^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT
THE VEHICLE FROM FALLING.
^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND
FALLING OFF THE JACK.
^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE
WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF
THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL
TRANSMISSION).
Jacking Points - Front
1. The front jacking point is a tab that extends from the lower control arm.
1. The rear jacking points are located on the rear axle tube.
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle
cover and adjoining differential housing surface may occur if a floor jack or any lifting device is
allowed to contact the cover at any point where the cover joins the housing.
LIFTING
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 8050
Lifting Points - 4x4
1. Locate front and rear hoist adapters on bottom lifting points as indicated.
CAUTION: ^
Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
^ Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8059
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8060
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8061
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8062
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8063
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8064
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8065
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8066
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8067
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8068
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance
Tires: Recalls Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8077
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8078
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8079
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8080
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8081
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8082
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8083
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 8089
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8094
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8095
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8096
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8097
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8098
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8099
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8100
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8101
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8102
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8103
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement
Technical Service Bulletin # 00L12 Date: 010101
Information
00L12
SPECIAL FIELD ACTION
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Original - January 2001
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1, February 5, 2001 - Updated Information
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Supplement # 2, February 19, 2001 - Updated Information
All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8108
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8109
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8110
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8111
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8112
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8113
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8114
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8115
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8116
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8117
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8118
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8119
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8120
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8121
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8122
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8123
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8124
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8125
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8126
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8127
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8128
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8129
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8130
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8131
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000:
Certification Label Non-Compliance
Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8140
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8141
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8142
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8143
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8144
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8145
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8146
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 8152
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement
Technical Service Bulletin # 00L12 Date: 010101
Information
00L12
SPECIAL FIELD ACTION
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Original - January 2001
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1, February 5, 2001 - Updated Information
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Supplement # 2, February 19, 2001 - Updated Information
All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8157
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8158
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8159
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8160
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8161
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8162
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8163
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8164
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8165
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8166
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8167
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8168
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8169
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8170
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8171
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8172
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8173
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8174
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8175
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8176
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8177
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8178
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8179
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8180
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Page 8181
Tires: Specifications
General Specifications
Wheel Rim Runout
Tire Runout Specifications
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Page 8182
Tires: Service and Repair
Removal
1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and
wheel bearings.
NOTE: To avoid damage or scratching to the center cap, place facing up when removed.
Loosen the wheel nuts.
1 Remove the center cap.
2 With the weight of the vehicle on the wheels, loosen the wheel nuts.
2. Raise and support the vehicle. 3. Remove the wheel and tire assembly.
1 Remove the wheel nuts.
2 Remove the wheel and tire assembly, using a side-to-side rocking motion.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel
nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are
loosened.
WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off
while the vehicle is in motion, possibly causing loss of vehicle control and collision.
Clean the wheel hub mounting surface and wheel pilot.
2. Install the tire and wheel assembly.
1 Position the tire and wheel assembly.
2 Install the wheel nuts hand-tight, then lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Page 8183
3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake
roughness, shudder and vibration.
Tighten the wheel nuts in a star pattern, using a torque wrench or torque sticks.
4. Install the center cap.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance
Wheels: Recalls Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force
Measurement Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force
Measurement Equipment > Page 8197
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA00V313000 > Oct > 00 > Recall 00V313000:
Certification Label Non-Compliance
Wheels: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 8207
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Page 8208
Wheels: Specifications
General Specifications
Wheel Rim Runout
Tire Runout Specifications
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and
Repair > Wheel and Tire
Wheels: Service and Repair Wheel and Tire
Removal
1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and
wheel bearings.
NOTE: To avoid damage or scratching to the center cap, place facing up when removed.
Loosen the wheel nuts. 1
Remove the center cap.
2 With the weight of the vehicle on the wheels, loosen the wheel nuts.
2. Raise and support the vehicle.
3. Remove the wheel and tire assembly.
1 Remove the wheel nuts.
2 Remove the wheel and tire assembly, using a side-to-side rocking motion.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel
nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are
loosened.
WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off
while the vehicle is in motion, possibly causing loss of vehicle control and collision.
Clean the wheel hub mounting surface and wheel pilot.
2. Install the tire and wheel assembly.
1 Position the tire and wheel assembly.
2 Install the wheel nuts hand-tight, then lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and
Repair > Wheel and Tire > Page 8211
3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake
roughness, shudder and vibration.
Tighten the wheel nuts in a star pattern, using a torque wrench or torque sticks.
4. Install the center cap.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and
Repair > Wheel and Tire > Page 8212
Wheels: Service and Repair Wheel Leaks
1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications
- Lubricate the new rear wheel bearing. ^
For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
- Lubricate the lip of the new wheel bearing oil seal. ^
Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications > Page 8216
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of
the following actions.
^ On 4x2 vehicles, adjust the front wheel bearings.
^ On 4x4 vehicles, install a new wheel hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Ford
Wheel Bearing: Service and Repair Ford
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake
Special Tools
Special Tool(s)
Removal
1. Remove the axle shaft.
2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with
foreign material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.
Installation
1. Lubricate the new rear wheel bearing.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Ford > Page 8219
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake
Special Tool(s)
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Ford > Page 8220
NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or
equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
- Tighten the spindle nut while rotating the brake disc and hub.
- Loosen the spindle nut.
- Tighten the spindle nut while rotating the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel Nuts 135 Nm (100 lb/ft)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front
Wheel Fastener: Service and Repair Front
Removal
1. Remove the brake disc and hub.
2. CAUTION: Place shop towels between the pry bars and the brake disc to prevent damage to the
disc surface.
Using two pry bars, remove the ABS sensor ring. Discard the ABS sensor ring.
3. Using a suitable press, remove the wheel stud from the brake disc and hub.
Installation
1. Using a suitable press, install the wheel stud in the brake disc and hub.
2. CAUTION: When installing the ABS sensor ring, make sure the sensor ring is pressed on
straight.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 8230
Position a new ABS sensor ring on the hub. Using a cylinder with 79 mm (3.16 inch) inside
diameter and 96 mm (3.84 inch) outside diameter, press the ring onto the hub until the ring seats
against the shoulder in the hub.
3. Install the brake disc and hub.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 8231
Wheel Fastener: Service and Repair Rear
Special Tool(s)
Special Tool(s)
Removal
CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange,
wheel bearing or hub bearing can result.
1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove
the rear disc brake caliper, rear disc support bracket and brake disc, if so equipped. Support the
rear disc brake caliper with safety wire.
4. Using the C-Frame and Screw Assembly, press the wheel stud from its seat and discard.
Installation
CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud.
1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned
with those made by the original wheel stud.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 8232
2. Seat new wheel studs in the axle flange.
- Place four flatwashers over the outside end of the wheel stud.
- Thread a standard wheel nut with the flat side against the washers.
- Tighten the wheel nut until the wheel stud head seats against the back side of the flange.
3. Remove the wheel nut and flatwashers. 4. Install the brake disc, rear disc support bracket and
the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the
vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service
Precautions
Accumulator HVAC: Service Precautions
CAUTION: Use a back-up wrench to prevent damage to the tubes.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service
Precautions > Page 8237
Accumulator HVAC: Description and Operation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
Suction Accumulator, Part 1
Suction Accumulator, Part 2
The suction accumulator is mounted on the A/C accumulator bracket to the right of the vehicle
centerline. The inlet tube of the suction accumulator attaches directly to the A/C evaporator core
outlet tube and the outlet tube attaches to the A/C manifold and tube.
After entering the inlet of the suction accumulator, the heavier oil-laden refrigerant contacts an
internally mounted dome (which serves as an umbrella)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service
Precautions > Page 8238
and drips down onto the bottom of the canister.
- A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated
heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate.
- As the heavier mixture passes through the small diameter liquid bleed hole, it has a second
chance to vaporize and recirculate through the A/C compressor without causing compressor
damage due to slugging.
- A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out
refrigerant system contaminant particles.
- A desiccant bag is mounted inside the canister to absorb any moisture which may be in the
refrigerant system.
- A fitting located on the top of the suction accumulator is used to attach the A/C cycling switch. A
long-travel Schrader- type valve stem core is installed in the fitting so that the A/C cycling switch
can be removed without discharging the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service
Precautions > Page 8239
Accumulator HVAC: Service and Repair
REMOVAL
1. Prepare the vehicle for suction accumulator/drier removal.
1 Disconnect the battery ground cable.
2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant.
3 Remove the air cleaner assembly.
2. Detach the speed control servo.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Position the speed control servo aside.
3. Position the coolant expansion tank/windshield washer reservoir aside.
1 Remove the screws and the nuts.
2 Position the coolant expansion tank/windshield washer reservoir aside.
4. Disconnect the A/C cycling switch electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service
Precautions > Page 8240
5. Disconnect the suction accumulator/drier refrigerant lines.
CAUTION: Use a back-up wrench to prevent damage to the tubes.
6. Remove the two screws and the suction accumulator/drier.
INSTALLATION
1. To install, reverse the removal procedure.
- If a new suction accumulator/drier is to be installed, transfer the A/C cycling switch to the new
suction accumulator/drier.
- If a new suction accumulator/drier is to be installed, refer to refrigerant oil addition. See:
Refrigerant Oil Addition.
2. Evacuate, leak test, and charge the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service
Precautions > Page 8241
Accumulator HVAC: Tools and Equipment
Spring Lock Coupling Disconnect Tool Set
Spring Lock Coupling Disconnect Tool Set
Disconnect Tool, Spring Lock Coupling
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and
Repair
Air Conditioning Switch: Service and Repair
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations
Air Door Actuator / Motor: Locations
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Page 8249
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Page 8250
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Page 8251
Air Door Actuator / Motor: Service Precautions
CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Description and Operation > Blend Door Motor
Air Door Actuator / Motor: Description and Operation Blend Door Motor
The A/C electronic blend door actuator is located on the rear of the A/C evaporator housing.
- Its function is to move the air temperature blend doors on command from the temperature control
switch.
- The A/C electronic blend door actuator contains a reversible electric motor and a potentiometer.
The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft
to indicate the position of the air temperature blend door.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Description and Operation > Blend Door Motor > Page 8254
Air Door Actuator / Motor: Description and Operation Vacuum Control Motors
The vacuum control motors:
- are located on the A/C evaporator housing, A/C recirculating air duct and heater air plenum
chamber.
- direct system airflow to the vehicle interior as determined by the function selector switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor
Air Door Actuator / Motor: Service and Repair Blend Door Motor
REMOVAL
1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument
Panel : Service and Repair " See: Body
and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
2. Remove the A/C electronic door actuator motor.
- Remove the screws.
- Disconnect the harness connector and remove the A/C electronic door actuator motor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor > Page 8257
Air Door Actuator / Motor: Service and Repair Air Door Actuator / Motor, HVAC
Air Recirculation Door Vacuum Control Motor
REMOVAL
1. Release the stops and lower the glove compartment door to the floor.
2. Remove the screws and disconnect the vacuum hose.
3. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor.
CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break.
INSTALLATION
1. To install, reverse the removal procedure.
Panel/Defrost Door Vacuum Control Motor
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor > Page 8258
2. Remove the lower steering column opening finish panel.
1 Remove the screws. Detach the hood release handle.
2 Remove the two screws.
3 Pull out to release the retaining clips. Remove the lower steering column opening finish panel.
3. Remove the bolts and the lower steering column opening finish panel reinforcement.
4. Remove the two screws. Detach the relay panel.
5. Remove the screws. Disconnect the vacuum hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor > Page 8259
6. Rotate the vacuum control motor. Disengage the lever and remove the vacuum control motor.
CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break.
INSTALLATION
1. To install, reverse the removal procedure.
Panel/Floor Door Vacuum Control Motor
REMOVAL
1. Remove the lower steering column opening finish panel.
1 Remove the screws. Detach the hood release handle.
2 Remove the two screws.
3 Pull out to release the retaining clips. Remove the lower steering column opening finish panel.
2. Remove the bolts and the lower steering column opening finish panel reinforcement. 3. Remove
the two bolts and the floor console mounting bracket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor > Page 8260
4. Remove the screws. Disconnect the vacuum hose.
5. Rotate the vacuum control motor. Disengage the lever and remove the vacuum control motor.
CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct
Air Duct: Service and Repair Floor Duct
REMOVAL
1. Remove the second row climate control assembly.
2. Remove the screws and the rear floor duct.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct > Page 8265
Air Duct: Service and Repair Windshield Defroster and Side Window Demister Nozzle
REMOVAL
1. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument
Panel, Service and Repair, Removal and
Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair
2. Remove the two screws and remove the LH demister nozzle and duct.
3. Remove the two screws and remove the RH demister nozzle and duct.
4. Remove the screws and remove the windshield defroster hose nozzle.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct > Page 8266
1. Follow the removal procedure in reverse order.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister
Air Register: Service and Repair Defrost Nozzles and Side Demister
REMOVAL
1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument
Panel : Service and Repair " See: Body
and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
2. Remove the two screws and remove the LH demister nozzle and duct.
3. Remove the two screws and remove the RH demister nozzle and duct.
4. Remove the screws and remove the windshield defroster hose nozzle.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister > Page 8271
1. Follow the removal procedure in reverse order.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister > Page 8272
Air Register: Service and Repair Air Register
Center
REMOVAL
1. Remove the audio unit.
2. Remove the screws. Disengage the spring clips. Detach the instrument panel finish panel.
3. Disconnect the cigar lighter electrical connectors.
4. Disconnect the electrical connectors. Remove the instrument panel finish panel.
NOTE: The number and location of the electrical connectors will vary dependent on vehicle
equipment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister > Page 8273
5. Release the eight clips. Remove the center instrument panel register from the instrument panel
finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Driver Side
REMOVAL
1. Remove the LH instrument panel finish panel.
2. Remove the LH instrument panel register.
1 Remove the screws.
2 Remove the LH instrument panel register.
INSTALLATION
1. Follow the removal procedure in reverse order.
Passenger Side
REMOVAL
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister > Page 8274
1. Lift the edge of the RH instrument panel register to expose the retainers.
2. Release the retainers and remove the RH instrument panel register.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations
Blower Motor: Locations
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8278
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions
Blower Motor: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8281
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8282
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8283
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8284
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8285
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8286
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8287
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8288
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8289
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8290
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8291
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8292
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8293
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8294
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8295
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8296
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8297
Blower Motor: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8299
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8300
Blower Motor: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8301
Blower Motor: Electrical Diagrams
DETAILED DIAGRAMS
Diagram 412-00-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8302
Diagram 412-00-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8303
Diagram 412-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8304
Diagram 412-00-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8305
Diagram 412-00-00-5
RELATED DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8306
Diagram 413-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 8307
Diagram 413-00-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8308
Blower Motor: Service Precautions
CAUTION: Do not attempt to bend the second row climate control assembly arm.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8309
Blower Motor: Description and Operation
The blower motor pulls air from the air inlet and forces it into the plenum assembly where it is
mixed and distributed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8310
Blower Motor: Testing and Inspection
For further information regarding this component please refer to:
Heating and Air Conditioning; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front
Blower Motor: Service and Repair Front
Blower Motor - Front
REMOVAL
1. Prepare the vehicle for blower motor removal.
1 Disconnect the battery ground cable.
2 Remove the air cleaner assembly.
2. Detach the speed control servo.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Position the speed control servo aside.
3. Position the coolant expansion tank/windshield washer reservoir aside.
1 Remove the screws and the nuts.
2 Position the coolant expansion tank/windshield washer reservoir aside.
4. Remove the blower motor.
1 Disconnect the vent hose.
2 Disconnect the electrical connector.
3 Remove the four screws.
4 Remove the blower motor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8313
Blower Motor: Service and Repair Second Row
Blower Motor - Second Row
REMOVAL
1. Remove the floor console.
2. Remove the coin tray.
3. Remove the screws and the console insert.
4. Remove the screw and the console lid.
5. Remove the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8314
6. Open the rear cupholder. Remove the screws.
7. Remove the two screws.
8. Disengage the retaining clips. Remove the console rear finish panel.
9. Remove the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8315
10. Disconnect the electrical connectors. Disengage the pin-type retainer.
11. Disconnect the air distribution door linkage from the second row climate control assembly arm.
Remove the second row climate control assembly.
CAUTION: Do not attempt to bend the second row climate control assembly arm.
12. Remove the screws and the console rear air distribution duct.
13. Remove the nine screws and the console liner.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8316
14. Remove the nuts.
15. Remove the screws.
16. Remove the two screws.
17. Disconnect the blower motor resistor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8317
18. Disengage the pin-type retainer.
19. Slide the console reinforcement rearward. Partially remove the blower motor and air distribution
duct assembly.
20. Disconnect the blower motor electrical connector.
21. Remove the screws. Remove the blower motor assembly from the console air distribution duct.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8318
1. Align the blower motor assembly with the console air distribution duct. Install the screws.
2. Connect the blower motor electrical connector. 3. Position and align the studs of the blower
motor and air distribution duct assembly to the console reinforcement.
4. Slide the console reinforcement forward.
5. Engage the pin-type retainer.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8319
6. Connect the blower motor resistor electrical connector.
7. Install the two screws.
8. Install the two screws.
9. Install the nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8320
10. Install the console liner and the nine screws.
11. Install the console rear air distribution duct and the screws.
12. Connect the air distribution door linkage to the second row climate control assembly arm.
CAUTION: Do not attempt to bend the second row climate control assembly arm.
13. Connect the electrical connectors. Engage the pin-type retainer.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8321
14. Position the second row climate control assembly. Install the screws.
15. Align the console rear finish panel to the floor console. Engage the retaining clips.
16. Install the screws.
17. Install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Front > Page 8322
18. Install the screws.
19. Install the console lid and the screw.
20. Install the console insert and the screws.
21. Install the coin tray. 22. Install the floor console.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations
Blower Motor Relay: Locations
Diagram 700-01-00-1
Diagram 700-01-00-5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Page 8326
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Page 8327
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > High
Speed Fan Control Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > High
Speed Fan Control Relay > Page 8330
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Page 8331
Blower Motor Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Page 8332
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
Blower Motor Resistor: Locations
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 8336
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Front > Page 8339
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Page 8340
Blower Motor Resistor: Description and Operation
The front heater blower motor switch resistor has the following features:
- The assembly is located in the engine compartment on the evaporator housing next to the blower
motor assembly.
- Three resistor elements are mounted on the resistor board to provide four blower motor speeds.
- Depending on the heater blower motor switch position, series resistance is added or bypassed in
the A/C blower motor circuit to decrease or increase A/C blower motor speed.
- An overheating device (thermal limiter) will open the resistor coil circuit when the temperature
reaches 121°C (250°F), interrupting the blower motor operation in all speeds except high.
- The thermal limiter cannot be reset and is not serviceable.
The second row heater blower motor switch resistor has the following features:
- The assembly is located in the high-series flow-through floor console next to the blower motor
assembly.
- There is one resistor element are mounted on the resistor board to provide two blower motor
speeds.
- Depending on the heater blower motor switch position, series resistance is added or bypassed in
the A/C blower motor circuit to decrease or increase A/C blower motor speed.
- An overheating device (thermal limiter) will open the resistor coil circuit when the temperature
reaches 121°C (250°F), interrupting the blower motor operation in all speeds.
- The thermal limiter cannot be reset and is not serviceable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Front
Blower Motor Resistor: Service and Repair Front
Blower Motor Resistor - Front
REMOVAL
1. Prepare the vehicle for heater blower motor switch resistor removal.
1 Disconnect the battery ground cable.
2 Remove the air cleaner assembly.
2. Detach the speed control servo.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Position the speed control servo aside.
3 Position the coolant expansion tank/windshield washer reservoir aside. 1
Remove the screws and nuts.
2 Position the reservoir aside.
4. Disconnect the heater blower motor switch resistor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Front > Page 8343
5. Remove the screws and the heater blower motor switch resistor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Front > Page 8344
Blower Motor Resistor: Service and Repair Second Row
Blower Motor Resistor - Second Row
REMOVAL
1. Remove the floor console.
2. Disconnect the heater blower motor switch resistor electrical connector.
3. Remove the screws and the heater blower motor switch resistor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams
Blower Motor Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams >
Page 8348
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams >
Page 8349
Blower Motor Switch: Description and Operation
Function Selector Switch
The function selector switch combines a vacuum selector valve with two electrical switches to
supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit.
Temperature Control Switch
Temperature selection is accomplished with a potentiometer connected to the electric blend door.
Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a
corresponding movement on the air temperature that the air system will maintain.
Blower Motor Switch
The blower motor switch controls blower motor speed by adding or by passing resistors in the
heater blower motor switch resistor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams >
Page 8350
Blower Motor Switch: Service and Repair
CLIMATE CONTROL ASSEMBLY-FRONT SWITCHES
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
Air Gap Between Pulley And Clutch Plate
.......................................................................................................................... 0.35-0.75 mm
(0.014-0.030 in)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions
Compressor Clutch: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8360
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8361
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8362
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8363
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8364
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8365
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8366
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8367
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8368
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8369
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8370
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8371
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8372
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8373
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8374
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8375
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8376
Compressor Clutch: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8377
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8378
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8379
Compressor Clutch: Electrical Diagrams
DETAILED DIAGRAMS
Diagram 412-00-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8380
Diagram 412-00-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8381
Diagram 412-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8382
Diagram 412-00-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8383
Diagram 412-00-00-5
RELATED DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8384
Diagram 413-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Diagram Information and Instructions > Page 8385
Diagram 413-00-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8386
Compressor Clutch: Service Precautions
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8387
Compressor Clutch: Description and Operation
NOTE:
- Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is
serviced only as an assembly. The A/C clutch, A/C clutch pulley , A/C clutch field coil and the shaft
seal are serviceable.
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The magnetic A/C clutch has the following characteristics:
- It drives the compressor shaft.
- When battery positive voltage (B+) is applied to the A/C clutch field coil, the A/C clutch is drawn
toward the A/C clutch pulley.
- The magnetic force locks the A/C clutch and the A/C clutch pulley together as one unit, causing
the compressor shaft to rotate.
- When B+ is removed from the A/C clutch field coil, springs in the A/C clutch move the A/C clutch
away from the A/C clutch pulley.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8388
Compressor Clutch: Testing and Inspection
For further information regarding this component please refer to:
Heating and Air Conditioning; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8389
Compressor Clutch: Adjustments
1. Check the A/C clutch air gap at three equally-spaced places between the A/C clutch hub and the
A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and
the compressor shaft until clearance is within specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8390
Compressor Clutch: Service and Repair
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
1. Remove the A/C compressor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8391
2. Remove the bolt.
1 Hold the A/C clutch hub with the special tool.
2 Remove the bolt.
3. Remove the A/C clutch and the A/C clutch hub spacer.
1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft.
2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft.
4. Remove the pulley snap ring.
5. Remove the A/C clutch pulley.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8392
6. Remove the A/C clutch field coil.
1 Note the location of the A/C clutch field coil electrical connector.
2 Install the special tool on the nose opening of the A/C compressor.
3 Install the special tool.
4 Remove the A/C clutch field coil.
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
INSTALLATION
1. Clean the A/C clutch field coil and pulley bearing mounting surfaces.
2. Install the A/C clutch field coil.
1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical
connector correctly positioned.
2 Place the special tool on the A/C clutch field coil.
3 Place the special tool on the special tool.
4 Use the special tool to install the A/C clutch field coil until bottomed completely against the A/C
compressor.
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
3. Install the A/C clutch pulley.
NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned
during installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8393
4. Install the pulley snap ring with the bevel side out.
5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.
6. Install the A/C clutch.
7. Install the bolt.
1 Hold the A/C clutch hub with the special tool.
2 Tighten the bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8394
8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install
the A/C compressor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Diagrams > Page 8395
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 8399
Compressor Clutch Coil: Service and Repair
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
1. Remove the A/C compressor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 8400
2. Remove the bolt.
1 Hold the A/C clutch hub with the special tool.
2 Remove the bolt.
3. Remove the A/C clutch and the A/C clutch hub spacer.
1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft.
2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft.
4. Remove the pulley snap ring.
5. Remove the A/C clutch pulley.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 8401
6. Remove the A/C clutch field coil.
1 Note the location of the A/C clutch field coil electrical connector.
2 Install the special tool on the nose opening of the A/C compressor.
3 Install the special tool.
4 Remove the A/C clutch field coil.
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
INSTALLATION
1. Clean the A/C clutch field coil and pulley bearing mounting surfaces.
2. Install the A/C clutch field coil.
1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical
connector correctly positioned.
2 Place the special tool on the A/C clutch field coil.
3 Place the special tool on the special tool.
4 Use the special tool to install the A/C clutch field coil until bottomed completely against the A/C
compressor.
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
3. Install the A/C clutch pulley.
NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned
during installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 8402
4. Install the pulley snap ring with the bevel side out.
5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.
6. Install the A/C clutch.
7. Install the bolt.
1 Hold the A/C clutch hub with the special tool.
2 Tighten the bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 8403
8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install
the A/C compressor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 8404
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions
Compressor Shaft Seal: Service Precautions
CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials
to enter the A/C compressor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8408
Compressor Shaft Seal: Service and Repair
SPECIAL TOOL(S)
REMOVAL
1. Remove the A/C clutch from the A/C compressor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8409
2. Remove the shaft seal felt from the nose of the A/C compressor with the special tool. 3. Clean
the compressor nose area.
4. Insert the tip of the special tool into one of the snap ring eyes.
5. Rotate the special tool to position the tool tip and the snap ring eye closest to the A/C
compressor shaft.
6. Pull the special tool up quickly while keeping the tool shaft against the side of the nose opening
and remove the snap ring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8410
7. Engage the special tool into the inside diameter of the shaft seal.
8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal.
9. Pull the seal from the A/C compressor.
INSTALLATION
1. Clean the A/C compressor nose area.
CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials
to enter the A/C compressor.
2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with PAG oil
or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8411
3. Position the shaft seal and the special tool over the A/C compressor shaft.
4. Push the shaft seal onto the A/C compressor shaft with the special tool until seated.
5. Install the shaft seal snap ring. 6. Carry out the A/C Compressor External Leak Test. See:
Testing and Inspection/External Leak Test
7. Install the shaft seal felt. 8. Install the A/C clutch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8412
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 8416
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 8417
Compressor Clutch Relay: Description and Operation
WIDE OPEN THROTTLE A/C CUT-OFF
The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally
open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)).
If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant
temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C
(WAC) output, closing the relay contacts and sending voltage to the A/C clutch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 8418
Compressor Clutch Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 8419
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Description and Operation
Compressor Fitting HVAC: Description and Operation
The A/C manifold and tube is attached to the A/C compressor, is sealed with O-ring seals, and has
the following features:
- The upstream side contains low pressure refrigerant gas.
- The downstream side contains high pressure refrigerant gas and a fitting used to mount a
serviceable high-pressure A/C charge port valve.
- The downstream side also contains a fitting used to mount the A/C pressure cutoff switch. A
long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cutoff
switch can be removed without discharging the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Description and Operation > Page 8423
Compressor Fitting HVAC: Service and Repair
REMOVAL
1. Prepare the vehicle for A/C manifold and tube removal.
1 Disconnect the battery ground cable.
2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant.
3 Remove the air cleaner assembly.
4 Remove the A/C compressor.
2. Disconnect the A/C pressure cut-off switch electrical connector.
3. Disconnect the A/C manifold and tube from the A/C condenser core. Remove and discard the
O-ring seal.
- During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification
WSH-M1C231-B.
4. Disconnect the A/C manifold and tube spring lock coupling.
- During installation, install new O-ring seals lubricated with PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification
WSH-M1C231-B.
5. Raise and support the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Description and Operation > Page 8424
6. Remove the bolt. Detach the A/C manifold and tube. 7. Lower the vehicle. 8. Remove the A/C
manifold and tube from the vehicle.
INSTALLATION
1. To install, reverse the removal procedure.
- If a new A/C manifold and tube is to be installed, transfer the A/C pressure cut-off switch to the
new A/C manifold and tube.
2. Evacuate, leak test, and charge the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Description and Operation > Page 8425
Compressor Fitting HVAC: Tools and Equipment
Spring Lock Coupling Disconnect Tool (5/8 Inch)
Disconnect Tool, Spring Lock Coupling
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Description and Operation > Page 8426
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation
Condenser HVAC: Description and Operation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The A/C condenser core has the following characteristics:
- It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator.
- It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and
condense refrigerant gas to liquid refrigerant as it is cooled.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 8430
Condenser HVAC: Testing and Inspection
On-Vehicle Leak Test
1. Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 2.
Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system.
NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the
core tubes.
3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air
Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red
and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core
or A/C condenser core.
Connect the yellow hose to a known good vacuum pump.
NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are
used, make sure the valve opens when attached to the test fittings or install an adapter which will
activate the valve. The test is not valid if the shut-off valve does not open.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
Pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before installing a new A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101
kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 8431
Condenser HVAC: Service and Repair
REMOVAL
NOTE:
- Installation of a new suction accumulator/drier is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator/drier.
- If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it
is removed from the vehicle.
1. Prepare the vehicle for A/C condenser core removal.
1 Disconnect the battery ground cable.
2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant.
3 Remove the air cleaner assembly.
2. Disconnect the A/C manifold and tube from the A/C condenser core. Remove and discard the
O-ring seal.
- During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification
WSH-M1C231-B.
3. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard
the O-ring seal.
- During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification
WSH-M1C231-B.
4. Raise the vehicle.
5. Remove the lower air deflector.
1 Remove the seven screws.
2 Remove the two pin-type retainers and the air deflector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 8432
6. Remove the metallic Clip. Detach the transmission oil cooler lines.
7. Remove the bolt.
8. Remove the bolt and the A/c condenser core.
INSTALLATION
1. To install, reverse the removal procedure.
- If a new A/C condenser core is to be installed, refer to refrigerant oil addition. See: Refrigerant Oil
Addition.
- If a new A/C condenser core is to be installed, a new A/C evaporator core orifice should also be
installed.
2. Evacuate, leak test, and charge the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 8433
Condenser HVAC: Tools and Equipment
Spring Lock Coupling Disconnect Tool Set
Spring Lock Coupling Disconnect Tool Set
Disconnect Tool, Spring Lock Coupling
Heater Hose Disconnect Tool
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 8434
Special Tool(s)
Set, A/C Fittings
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
Control Assembly: Locations
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Page 8438
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions
Control Assembly: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8441
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8442
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8443
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8444
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8445
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8446
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8447
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8448
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8449
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8450
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8451
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8452
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8453
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8454
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8455
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8456
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8457
Control Assembly: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8458
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8459
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8460
Control Assembly: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8461
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8462
Control Assembly: Electrical Diagrams
DETAILED DIAGRAMS
Diagram 412-00-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8463
Diagram 412-00-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8464
Diagram 412-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8465
Diagram 412-00-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8466
Diagram 412-00-00-5
RELATED DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8467
Diagram 413-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8468
Diagram 413-00-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8469
Control Assembly: Vacuum and Vapor Hose Diagrams
Vacuum Schematic-Manual Climate Control System, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 8470
Vacuum Schematic-Manual Climate Control System, Part 2
Vacuum Connector End View - Manual A/C
Vacuum Application Chart-Manual A/C
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Main Climate Control
Control Assembly: Description and Operation Main Climate Control
The climate control assembly has three system controls:
1. Function Selector Switch
The function selector switch combines a vacuum selector valve with two electrical switches to
supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit.
2. Temperature Control Switch
Temperature selection is accomplished with a potentiometer connected to the electric blend door.
Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a
corresponding movement on the air temperature that the air system will maintain.
3. Blower Motor Switch
The blower motor switch controls blower motor speed by adding or by passing resistors in the
heater blower motor switch resistor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Main Climate Control > Page 8473
Control Assembly: Description and Operation Temperature Control Switch
Temperature Control Switch
Temperature selection is accomplished with a potentiometer connected to the electric blend door.
Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a
corresponding movement on the air temperature that the air system will maintain.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > System Testing
Control Assembly: Testing and Inspection System Testing
For further information regarding this component please refer to :
Heating and Air Conditioning; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > System Testing > Page 8476
Control Assembly: Testing and Inspection Component Tests
Vacuum Schematic-Manual Climate Control System, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > System Testing > Page 8477
Vacuum Schematic-Manual Climate Control System, Part 2
Vacuum Connector End View - Manual A/C
Vacuum Application Chart-Manual A/C
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control
Control Assembly: Service and Repair Main Climate Control
REMOVAL
1. Remove the audio unit.
2. Remove the screws. Disengage the spring clips. Detach the instrument panel finish panel.
3. Disconnect the cigar lighter electrical connectors.
4. Disconnect the electrical connectors. Remove the instrument panel finish panel.
NOTE: The number and location of the electrical connectors will vary dependent on vehicle
equipment.
5. Remove the screws and the climate control assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 8480
6. Disconnect the climate control assembly.
- Disconnect the electrical connectors.
- Disconnect the vacuum harness connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 8481
Control Assembly: Service and Repair Auxiliary Climate Control
REMOVAL
1. Remove the floor console.
2. Remove the coin tray.
3. Remove the screws and the console insert.
4. Remove the screw and the console lid.
5. Remove the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 8482
6. Open the rear cupholder. Remove the screws.
7. Remove the two screws.
8. Disengage the retaining clips. Remove the console rear finish panel.
9. Remove the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 8483
10. Disconnect the electrical connectors. Disengage the pin-type retainer.
11. Disconnect the air distribution door linkage from the second row climate control assembly arm.
Remove the second row climate control assembly.
CAUTION: Do not attempt to bend the second row climate control assembly am.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 8484
Control Assembly: Service and Repair Control Assembly Bulbs
REMOVAL
1. Remove the climate control assembly.
2. Turn and pull the lamp socket.
- Install a new bulb in the socket.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 8485
Control Assembly: Service and Repair Temperature Control Switch
CLIMATE CONTROL ASSEMBLY-FRONT SWITCHES
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > Climate Control - Blower Control Service Tips
Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > Climate Control - Blower Control Service Tips > Page 8490
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > Climate Control - Blower Control Service Tips > Page 8491
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut
Fitting
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut
Fitting > Page 8496
Spring Lock Coupling
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page
8497
Coupler HVAC: Service Precautions
CAUTION:
- Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the
O-ring seal grooves resulting in refrigerant leaks.
- Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can
cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks.
- Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial
scratches which may cause future leaks.
- Use only new green O-ring seals. The use of any O-ring seals other than specified may result in
intermittent leakage during vehicle operation.
- Support the female fitting with a wrench to prevent the tubes from twisting.
- Use only new purple O-ring seals. The use of any O-ring seals other than specified may result in
intermittent leakage during vehicle operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and
Operation > Spring Lock Coupling
Coupler HVAC: Description and Operation Spring Lock Coupling
Spring Lock Coupling
The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a
circular cage.
- When the coupling is connected together, the flared end of the female fitting slips behind the
garter spring inside the cage of the male fitting.
- The garter spring and cage then prevent the flared end of the female fitting from pulling out of the
cage.
- Three O-ring seals are used to seal between the two halves of the spring lock couplings.
- These O-ring seals are green in color and are made of special material.
- Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock
coupling.
- A plastic indicator ring may be used on the spring lock couplings of the A/C evaporator core to
indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected,
the indicator ring is no longer necessary but will remain captive by the coupling near the cage
opening.
- The indicator ring may also be used during service operations to indicate connection of the
coupling.
- An A/C tube lock coupling clip may be used to secure the coupling but is not required.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and
Operation > Spring Lock Coupling > Page 8500
Coupler HVAC: Description and Operation Peanut Fitting
The A/C condenser core uses the peanut shaped refrigerant fittings instead of spring lock
couplings.
- The male and female blocks of the peanut fitting are retained with a nut.
- An O-ring seal is installed around the tube on the male block.
- The female block is welded to the tube and is not adjustable.
- Support the female fitting with a wrench to prevent twisting of the tubes.
- The male block will pivot around the tube to allow for alignment with the female block during
assembly.
- When correctly assembled the male and female fittings should be flush.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure
Coupler HVAC: Service and Repair Spring Lock Coupling Connect and Disconnect Procedure
Spring Lock Coupling
SPECIAL TOOL(S)
DISCONNECT
1. Remove the A/C tube lock coupling clip, if equipped.
2. Fit the special tool to the spring lock coupling.
3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling
spring.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 8503
4. Pull the spring lock coupling fittings apart.
5. Remove the O-ring seals with a non-metallic tool.
CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches
across the O-ring seal grooves resulting in refrigerant leaks.
6. Remove the A/C tube lock coupling spring with a small hooked wire.
CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring;
this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks.
CLEANING
1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 8504
2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions
corresponding to the coupling size.
3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil
(R-134a Systems) or equivalent. 5. Roll the pad on the tool and install it in a variable speed drill
motor.
6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and
free of scratches or foreign material.
CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent
axial scratches which may cause future leaks.
7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves
and scratches are still present, install a new component.
9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string.
- Loop the string around the grooves and pull the string back and forth.
10. Remove any foreign material from the grooves with a lint-free cloth.
CONNECT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 8505
1. Install the A/C tube lock coupling spring.
2. Lubricate the inside of the coupling with FAG Refrigerant Compressor Oil (R-134a Systems) or
equivalent.
3. Install the O-ring seals.
- Lubricate the O-ring seals with FAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may
result in intermittent leakage during vehicle operation.
4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling
spring snaps over the flared end of the female
fitting.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 8506
5. Install the A/C tube lock coupling clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 8507
Coupler HVAC: Service and Repair Peanut Fitting Connect and Disconnect Procedure
DISCONNECT
1. Remove the nut from the peanut fitting.
CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting.
2. Pull the peanut fitting apart.
3. Remove the O-ring seal with a non-metallic tool.
CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches
across the O-ring seal groove resulting in refrigerant leaks.
CONNECT
1. Clean all dirt or foreign material from the fittings.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 8508
2. Install the O-ring seal.
- Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
CAUTION: Use only new purple O-ring seals. The use of any O-ring seals other than specified may
result in intermittent leakage during vehicle operation.
3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent
meeting Ford specification WSH-M1C231-B.
4. Assemble the male and female fittings together.
NOTE: When correctly assembled, the male and female fittings should be flush.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and
Operation
Evaporator Case: Description and Operation
The evaporator core housing is located in the engine compartment.
The A/C evaporator housing assembly contains the following major components:
- A/C evaporator core
- blower motor
- blower motor resistor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and
Operation > Page 8512
Evaporator Case: Service and Repair
REMOVAL
NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator
core housing assembly. Replacement of the suction accumulator is not required when repairing the
refrigerant system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator. If an evaporator core leak is suspected, the
evaporator core must be leak tested before it is removed from the vehicle.
1. Remove the suction accumulator, please refer to Heating and Air Conditioning/ See:
Accumulator HVAC
2. Disconnect the blower motor and the blower motor resistor electrical connectors.
3. Detach the windshield wiper fluid hose. Using suitable hose pinching pliers, disconnect the
heater hoses.
4. Detach the heater control valve vacuum hose. 5. Disconnect the heater control valve vacuum
hose and the vacuum supply hose.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and
Operation > Page 8513
6. Disconnect the condenser to evaporator tube spring lock coupling.
7. Disconnect the vacuum harness connector. Remove the nut.
8. Remove two nuts, one bolt, and the A/C evaporator housing.
- Remove the nut located at the bottom of the A/C evaporator housing first.
- To remove the A/C evaporator housing, rotate the A/C evaporator housing counterclockwise.
Then tip the evaporator core end towards the front of the vehicle.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the refrigerant system with the correct amount of clean PAG Refrigerant Compressor
Oil (R-134a Systems) or equivalent. See: Refrigerant Oil Addition.
- Install new O-ring seals lubricated in amount of clean PAG Refrigerant Compressor Oil (R-134a
Systems) or equivalent.
- Lubricate the coolant hoses with MERPOL(R) or plain water only, if needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and
Operation > Page 8514
Evaporator Case: Tools and Equipment
Heater Hose Disconnect Tool
Spring Lock Coupling Disconnect Tool (5/8 Inch)
Disconnect Tool, Spring Lock Coupling
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and
Operation > Page 8515
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation
Evaporator Core: Description and Operation
NOTE:
- The evaporator core is not separately serviceable, it is serviced only with the evaporator core
housing assembly.
- installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The A/C evaporator core is the plate/fin type with a unique refrigerant flow path.
- A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C
evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin
sections.
- The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end
of the A/C evaporator core.
- Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the
A/C evaporator core through the A/C evaporator core outlet tube.
- This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator
core.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 8519
Evaporator Core: Testing and Inspection
On-Vehicle Leak Test
1. Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 2.
Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system.
NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the
core tubes.
3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air
Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red
and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core
or A/C condenser core.
Connect the yellow hose to a known good vacuum pump.
NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are
used, make sure the valve opens when attached to the test fittings or install an adapter which will
activate the valve. The test is not valid if the shut-off valve does not open.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
Pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before installing a new A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101
kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 8520
Evaporator Core: Service and Repair
REMOVAL
NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator
core housing assembly. Installation of a new suction accumulator is not required when repairing the
air conditioning system except when there is physical evidence of system contamination from a
failed A/C compressor or damage to the suction accumulator. If an evaporator core leak is
suspected, the evaporator core must be leak tested before it is removed from the vehicle.
1. Remove the evaporator core housing, please refer to heating and Air Conditioning/Evaporator
Case/Service and Repair/ See: Evaporator
Case/Service and Repair
2. Transfer components from the old evaporator core housing to the new evaporator core housing.
INSTALLATION 1. Install the evaporator core housing.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 8521
Evaporator Core: Tools and Equipment
Spring Lock Coupling Disconnect Tool Set
Spring Lock Coupling Disconnect Tool Set
Disconnect Tool, Spring Lock Coupling
Heater Hose Disconnect Tool
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 8522
Special Tool(s)
Set, A/C Fittings
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Diagrams > Page 8526
Expansion Block/Orifice Tube: Description and Operation
NOTE: A new A/C evaporator core orifice should be installed whenever a new A/C compressor is
installed.
The A/C evaporator core orifice has the following characteristics:
- It is color coded red.
- It is located in the A/C evaporator core inlet tube.
- It has filter screens located on the inlet and outlet ends of the tube body.
- The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C
evaporator core orifice.
- O-rings on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from
bypassing the A/C evaporator core orifice.
- Adjustment or service cannot be made to the A/C evaporator core orifice assembly. A new
evaporator core orifice assembly must be installed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > With Damaged Evaporator Core Orifice
Expansion Block/Orifice Tube: Service and Repair With Damaged Evaporator Core Orifice
SPECIAL TOOL(S)
REMOVAL
1. Prepare the vehicle for evaporator core orifice removal.
1 Disconnect the battery ground cable.
2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant.
3 Remove the air cleaner assembly.
2. Detach the speed control servo.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Position the speed control servo aside.
3. Position the coolant expansion tank/windshield washer reservoir aside.
1 Remove the screws and the nuts.
2 Position the coolant expansion tank/windshield washer reservoir aside.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > With Damaged Evaporator Core Orifice > Page 8529
4. Disconnect the condenser to evaporator tube spring lock coupling.
5. Inspect the evaporator core orifice for damage.
6. Screw the end of the special tool into the broken evaporator core orifice.
7. Holding the special tool T-handle stationary, rotate the special tool body to remove the broken
evaporator core orifice.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > With Damaged Evaporator Core Orifice > Page 8530
1. Install new O-ring seals on the evaporator core orifice.
- Lubricate the new O-ring seals with PAG oil or equivalent.
2. Position the evaporator core orifice in the special tool.
3. Using the special tool, install the evaporator core orifice.
4. Install the coolant expansion tank/windshield washer reservoir.
1 Install the coolant expansion tank/windshield washer reservoir aside.
2 Install the screws and the nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > With Damaged Evaporator Core Orifice > Page 8531
5. Install the speed control servo.
1 Install the speed control servo.
2 Install the bolt.
3 Connect the electrical connector.
6. Restore the vehicle to operating condition.
1 Install the air cleaner assembly.
2 Connect the battery ground cable.
3 Evacuate, leak test, and charge the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > With Damaged Evaporator Core Orifice > Page 8532
Expansion Block/Orifice Tube: Service and Repair With Serviceable Evaporator Core Orifice
SPECIAL TOOL(S)
REMOVAL
1. Prepare the vehicle for evaporator core orifice removal.
1 Disconnect the battery ground cable.
2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant.
3 Remove the air cleaner assembly.
2. Detach the speed control servo.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Position the speed control servo aside.
3. Position the coolant expansion tank/windshield washer reservoir aside.
1 Remove the screws and the nuts.
2 Position the coolant expansion tank/windshield washer reservoir aside.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > With Damaged Evaporator Core Orifice > Page 8533
4. Disconnect the condenser to evaporator tube spring lock coupling.
5. Inspect the evaporator core orifice for damage.
6. Engage the special tool with the evaporator core orifice.
7. Holding the special tool T-handle stationary, rotate the special tool body to remove the
evaporator core orifice.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > With Damaged Evaporator Core Orifice > Page 8534
1. Install new O-ring seals on the evaporator core orifice.
- Lubricate the new O-ring seals with PAG oil or equivalent.
2. Position the evaporator core orifice in the special tool.
3. Using the special tool, install the evaporator core orifice.
4. Install the coolant expansion tank/windshield washer reservoir.
1 Install the coolant expansion tank/windshield washer reservoir aside.
2 Install the screws and the nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > With Damaged Evaporator Core Orifice > Page 8535
5. Install the speed control servo.
1 Install the speed control servo.
2 Install the bolt.
3 Connect the electrical connector.
6. Restore the vehicle to operating condition.
1 Install the air cleaner assembly.
2 Connect the battery ground cable.
3 Evacuate, leak test, and charge the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > Page 8536
Expansion Block/Orifice Tube: Tools and Equipment
Spring Lock Coupling Disconnect Tool Set
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations
Expansion Valve: Locations
For further information regarding this component please refer to:
Heating and Air Conditioning; Expansion Block/Orifice Tube.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page
8540
Expansion Valve: Service and Repair
For further information regarding this component please refer to:
Heating and Air Conditioning; Expansion Block/Orifice Tube.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and
Repair
Heater Control Valve: Service and Repair
REMOVAL
1. Prepare the vehicle for heater water control valve assembly removal.
1 Drain the engine coolant.
2 Remove the air cleaner assembly.
2. Disconnect the vacuum hose and heater hose.
3. Remove the retaining pins. Position the inner fender well access mat out of the way.
4. Disconnect the heater hose. Remove the bolt and the heater water control valve assembly.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the coolant hoses with MERPOL(R) meeting Ford specification ESE-M99B144-B or
plain water only, if needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
8552
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
8553
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 8559
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 8560
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 8561
Heater Core: Service Precautions
WARNING:
- CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY
TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE,
ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE
CLOSED AREA.
THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS
WORKING CORRECTLY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 8562
Heater Core: Description and Operation
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 8563
Heater Core: Testing and Inspection
WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS
NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED ARE IN SUCH AS
A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES
OUTSIDE THE CLOSED AREA.
1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow
the heater core tube to the heater core and appear as a leak in the heater core.
NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good
and did not require installation of a new heater core. If a heater core leak is suspected, the heater
core must be tested by following the plugged heater core component test before the heater core
pressure test. Carry out a system inspection by checking the heater system thoroughly as follows:
2. Check the integrity of the heater water hose clamps.
NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at the heater water hose connection and damage the
heater core.
Heater Core-Plugged
WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE
SYSTEM IS WORKING CORRECTLY.
1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the
heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose
to see if it is hot.
If it is not hot: the heater control valve is not working correctly.
- the heater core may have an air pocket.
- the heater core may be plugged.
- the thermostat is not working correctly.
Heater Core-Pressure Test Use Pressure Tester to carry out the pressure test. 1. Drain the coolant
from the cooling system.
NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water
hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter
BT-7422-A from the radiator/heater core
pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter
with hose clamps.
5. Attach the pump and gauge assembly from the Pressure Tester to the adapter. 6. Close the
bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7.
Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the
heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak,
remove the
heater core from the vehicle and carry out the bench test.
Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant
from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and
adapter to the core tubes. Then connect the radiator/heater core pressure
tester to the adapter.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 8564
4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 8565
Heater Core: Service and Repair
REMOVAL 1. Prepare the vehicle for heater core removal.
1 Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator
Case/Service and Repair/ See: Evaporator Case/Service and Repair
2 Remove the Dash Board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel,
Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair
3 Remove the Powertrain Control Module (PCM), please refer to Powertrain
Management/Computers and Controls/Engine Control Module/Service and Repair/ See: Powertrain
Management/Computers and Control Systems/Powertrain Control Module/Service and Repair
NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
2. Remove the PCM heat sink
1 Remove the ground strap screw.
2 Remove the heat sink.
3. Remove the four nuts from the engine side of the dash panel. Position the plenum chamber on
the vehicle floor.
4. Remove the heater core cover.
1 Remove the screws.
2 Remove the heater core cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 8566
5. Remove the heater core.
- During installation, be sure to install a new oval foam seal around the heater core inlet and outlet
tubes.
INSTALLATION 1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
8575
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
8576
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 8582
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 8583
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation
High Pressure Safety Valve HVAC: Description and Operation
An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube
to:
- relieve unusually high refrigerant system discharge pressure buildups. Refer to specifications
regarding operating pressure(s).
- prevent damage to the A/C compressor and other system components.
- avoid total refrigerant loss by closing after the excessive pressure has been relieved.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and
Operation
Hose/Line HVAC: Description and Operation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C
evaporator core orifice.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and
Operation > Page 8590
Hose/Line HVAC: Service and Repair
REMOVAL
1. Prepare the vehicle for condenser to evaporator tube removal.
1 Disconnect the battery ground cable.
2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant.
3 Remove the air cleaner assembly.
2. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard
the O-ring seal.
- During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification
WSH-M1C231-B.
3. Disconnect and remove the condenser to evaporator tube.
INSTALLATION
1. To install, reverse the removal procedure. 2. Evacuate, leak test, and charge the A/C system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and
Operation > Page 8591
Disconnect Tool Set, Spring Lock Coupling
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair
Housing Assembly HVAC: Service and Repair
REMOVAL 1. Prepare the vehicle for plenum chamber removal.
1 Remove the dash board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel,
Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair
2 Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator
Case/Service and Repair/ See: Evaporator Case/Service and Repair
3 Remove the Powertrain Control Module (PCM), please refer to Powertrain
Management/Computers and Controls/Engine Control Module/Service and Repair/ See: Powertrain
Management/Computers and Control Systems/Powertrain Control Module/Service and Repair
2. Remove the PCM heat sink.
1 Remove the ground strap screw.
2 Remove the PCM heat sink
3 Remove the four nuts and the plenum chamber.
NOTE: To ease the removal of the plenum chamber, first remove the nut located at the center of
the dash panel behind the engine cylinder block.
INSTALLATION 1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and
Operation
Receiver Dryer: Description and Operation
For further information regarding this component and the system that it is part of, please refer to:
Accumulator HVAC.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and
Operation > Page 8598
Receiver Dryer: Service and Repair
For further information regarding this component and the system that it is part of, please refer to:
Accumulator HVAC.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Capacity ...............................................................................................................................................
......................................................... 0.85 kg (30 oz)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 8603
Refrigerant: Fluid Type Specifications
A/C Refrigerant ....................................................................................................................................
....................................... R-134a Refrigerant YN-19
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions >
Customer Safety Information
Refrigerant: Customer Safety Information
WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT
POSSIBLE PERSONAL INJURY
.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions >
Customer Safety Information > Page 8606
Refrigerant: Environmental Impact Information
The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a
protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun.
Ozone Depletion Scientific research performed over the past 15 years links the release of
chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone
depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer
located in the stratosphere where they react with and destroy ozone molecules.
Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown
to lead to higher incidents of cancer as well as global warming. When viewed from a global
perspective, ozone depletion holds an enormous potential for damage.
Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of
the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial
but the same compound, when located at ground level, is harmful to humans, animals, crops and
vegetation.
Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with
nitrogen oxides (NOx) in the presence of sunlight and heat.
Montreal Protocol In response to the growing body of evidence demonstrating the detrimental
effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to
establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become
signatories to this agreement leading to an end of production of R12 in December, 1995, in all
developed countries.
As established by the Montreal Protocol, R12 production in developed countries has ceased.
Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned
production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to
control both the production and use of (CFC)s for refrigerant applications including mobile vehicle
air conditioning systems.
Additional Information Sources
For more complete and detailed explanations of the above policies, please refer to:
http://www.epa.gov/ozone/
Technician Certification Organizations providing technician refrigerant recovery and recycling
certification include:
National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2
Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/
International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX
76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/
Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041
Phone: 215-679-2220
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions >
Customer Safety Information > Page 8607
Fax: 215-541-4635 http://www.macsw.org/
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions >
Customer Safety Information > Page 8608
Refrigerant: Technician Safety Information
WARNING:
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE AIR BAG SYSTEM
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING ANY CLIMATE
CONTROL COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY, DISCONNECT THE
BATTERY GROUND CABLE AND WAIT ONE MINUTE.
CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY
TO OPERATE THE ENGINE WITH VEHICLE IN A CLOSED AREA SUCH AS A GARAGE,
ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE
CLOSED AREA.
R-134A IS CLASSIFIED AS A SAFE REFRIGERANT, BUT MISUSE CAN MAKE IT
DANGEROUS. THE FOLLOWING PRECAUTIONS MUST BE OBSERVED. ALWAYS WEAR SAFETY GOGGLES WHEN REPAIRING AN AIR CONDITIONING SYSTEM.
- AVOID CONTACT WITH LIQUID REFRIGERANT R-134A. R-134A VAPORIZES AT
APPROXIMATELY -25°C (-13°F) UNDER ATMOSPHERIC PRESSURE AND IT WILL FREEZE
SKIN TISSUE.
- NEVER ALLOW REFRIGERANT R-134A GAS TO ESCAPE IN QUANTITY IN AN OCCUPIED
SPACE. R-134A IS NON-TOXIC, BUT IT WILL DISPLACE THE OXYGEN NEEDED TO
SUPPORT LIFE.
- NEVER USE A TORCH IN AN ATMOSPHERE CONTAINING R-134A GAS. R-134A IS
NON-TOXIC AT ALL NORMAL CONDITIONS, BUT WHEN IT IS EXPOSED TO HIGH
TEMPERATURES, SUCH AS A TORCH FLAME, IT DECOMPOSES. ONE OF THE PRODUCTS
OF THE CHEMICAL BREAKDOWN IS A PHOSGENE GAS, WHICH IS HIGHLY TOXIC.
- DO NOT ALLOW ANY PORTION OF THE CHARGED AIR CONDITIONING SYSTEM TO
BECOME TOO HOT. THE PRESSURE IN AN AIR CONDITIONING SYSTEM RISES AS THE
TEMPERATURE RISES AND TEMPERATURES OF APPROXIMATELY 85°C (185°F) CAN BE
DANGEROUS.
- ALLOW THE ENGINE TO COOL SUFFICIENTLY PRIOR TO PERFORMING MAINTENANCE
OR SERIOUS BURNS AND INJURY CAN OCCUR.
DUE TO REFRIGERANT HAZARDS, ALWAYS WEAR SAFETY GOGGLES AND
NON-PENETRABLE GLOVES WHEN WORKING ON OR FLUSHING A/C SYSTEMS.
USE EXTREME CARE AND OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS RELATED
TO THE USE OF REFRIGERANTS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions >
Customer Safety Information > Page 8609
Refrigerant: Vehicle Damage Warnings
CAUTION:
To avoid damaging the vehicle or A/C components, the following precautions must be observed. The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging.
Failure to due so can contaminate the shop bulk refrigerant and other vehicles.
- Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These
two types of refrigerant must never be mixed. Doing so can damage the A/C system.
- Charge the A/C system with the engine running only at the low-pressure side to prevent
refrigerant slugging from damaging the A/C compressor.
- Use only R-134a refrigerant. Due to environmental concerns, when the air conditioning system is
drained, the refrigerant must be collected using refrigerant recovery/recycling equipment. Federal
law REQUIRES that R-134a be recovered into appropriate recovery equipment and the process be
conducted by qualified technicians who have been certified by an approved organization, such as
MACS, ASI, etc. Use of a recovery machine dedicated to R-134a is necessary to reduce the
possibility of oil and refrigerant incompatibility concerns. Refer to the instructions provided by the
equipment manufacturer when removing refrigerant from or charging the air conditioning system.
- Refrigerant R-134a must not be mixed with air for leak testing or used with air for any other
purpose above atmospheric pressure. R-134a is combustible When mixed with high concentrations
of air and higher pressures.
- A number of manufacturers are producing refrigerant products that are described as direct
substitutes for Refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely
damage the A/C components. If repair is required, use only new or recycled Refrigerant R-134a.
- Use a back-up wrench to prevent damage to the tubes.
To avoid contamination of the A/C system: Never open or loosen a connection recovering the refrigerant using approved equipment.
- When loosening a connection, if any residual pressure is evident, allow it to leak out before
opening the fitting.
- Perform the Refrigerant Discharging and Recovery Procedure on a system that has been opened
to install a new component or one that has discharged through leakage before charging.
- Seal open fittings with a cap or plug immediately after disconnecting a component from the
system.
- Clean the outside of the fittings thoroughly before disconnecting a component from the system.
- Do not remove the sealing caps from a new component until ready to install.
- Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil
container until ready to use, and install the cap immediately after using. Store the oil in a clean,
moisture-free container.
- Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal with
refrigerant oil before connecting.
- When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or
any sharp edges that can chafe the line.
- Tighten threaded fittings only to specifications. The steel and aluminum fittings used in the
refrigerant system will not tolerate overtightening.
- When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the
refrigerant lines or tubes.
- Do not open a refrigerant system or uncap a new component unless it is as close as possible to
room temperature. This will prevent condensation from forming inside a component that is cooler
than the surrounding air.
- Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If
the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all
the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other
cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful
in removing small traces of contamination from the air that might affect the leak detector.
- During normal A/C operation, oil is circulated through the system with the refrigerant, and a small
amount is retained in each component. If certain components of the system are removed for new
installation, some of the refrigerant oil will go with the component. To maintain the original total oil
charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part.
- If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12
recovery/recycling equipment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure
Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure
Special Tool(s)
SPECIAL TOOL(S)
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
Refrigerant System Recovery
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. 2. Connect
an R-134a A/C service center to the low- and high-pressure service gauge port valves.
NOTE: Some R-134a service centers require the use of an A/C manifold gauge set.
3. Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant from the
system following the operating instructions
provided by the equipment manufacturer.
4. Once the service center has recovered the vehicle A/C system refrigerant, close the service
center inlet valve (if equipped). Then switch off the
power supply.
5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system
vacuum level on the gauge. If the vacuum does not
decrease, disconnect the refrigerant center hose(s).
6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains
stable for two minutes. 7. Carry out the required repairs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 8612
Refrigerant: Service and Repair Identifying Refrigerants
Delux A/C Refrigerant Analyzer
SPECIAL TOOL(S)
1. Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the sample
for testing.
NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the
refrigeration system or storage containers prior to recovering or charging the refrigerant system.
2. The diagnostic tool will display one of the following:
- If the purity level of R-134a or R-12 is 98% or greater by weight, the green "PASS" light emitting
diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will
be displayed on the digital display.
- If refrigerants R-134a or R-12 do not meet the 98% purity levels, the red "FAIL" LED will light and
a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12,
R-22, and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light,
"Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting the user
of potential hazards. The weight concentrations of R-134a, R-12, R-22,and hydrocarbons will also
be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a or R-12 content is
98% or greater. The diagnostic tool eliminates the
effect of air when determining the refrigerant sample content because air is not considered a
contaminant, although air can affect A/C system performance. When the diagnostic tool has
determined that a refrigerant source is pure (R-134a or R-12 is 98% or greater by weight) and air
concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air
purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated. 5. Perform the Refrigerant Discharging and Recovery
Procedure to remove any contaminated refrigerant using suitable recovery-only equipment
designed for capturing and storing contaminated refrigerant.
CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or
R-12 recovery/recycling equipment.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 8613
Refrigerant: Service and Repair Handling of Contaminated Refrigerants
1. Perform the Refrigerant Discharging and Recovery Procedure to remove the contaminated
refrigerant using suitable recovery-only equipment
designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to
other vehicles.
- If this equipment is not available, contact an A/C repair facility in your area with the correct
equipment to carry out this repair.
CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your
recovery/recycling equipment.
2. Determine and correct the cause of the customer's initial concern. 3. The suction
accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed.
Remove the suction accumulator/drier.
NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured for
correct oil system matching. See: Refrigerant Oil Addition.
4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction
accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8.
Dispose of contaminated refrigerant according to all federal, state and local regulations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 8614
Refrigerant: Service and Repair Evacuation and Charging
Special Tool(s)
SPECIAL TOOL(S)
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
Refrigerant System Evacuation
1. Connect an R-134a service center to the low- and high-pressure service gauge port valves. 2.
Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum
and as close to 101.1 kPa (30 in-Hg) as
possible. Continue to operate the vacuum pump for a minimum of 45 minutes.
3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that
the system vacuum is held. If vacuum is not held
for five minutes, leak test the system, service the leak, and evacuate the system again.
Refrigerant System Charging
1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the
system. See: Refrigerant Oil Addition. 2. Charge the system with the specified amounts of
refrigerant oil and refrigerant. 3. When no more refrigerant is being drawn into the system, start the
engine and select MAX A/C operation. Adjust the blower motor speed to the
maximum and allow the remaining refrigerant to be drawn into the system. Continue to add
refrigerant into the system until the specified weight of R-134a has been added. Close the charging
cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the
low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 8615
Refrigerant: Service and Repair Leak Detection
Electronic Leak Detection
Refrigerent Leak Detector
SPECIAL TOOL(S)
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be
carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate
this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake
cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated
area, is very helpful in removing small traces of contamination from the air that might affect the leak
detector.
1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and
operation techniques.
NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
2. If a leak is found, Perform the Refrigerant Discharging and Recovery Procedure to remove the
refrigerant.
- Repair the system.
- Test the system for normal operation.
Tracer Dye Leak Detection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 8616
120 Watt 110 Volt UV Lamp 20 Degree Celsius
SPECIAL TOOL(S)
NOTE: Ford Motor Company vehicles are produced with a permanent leak tracer dye incorporated
into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the
tracer dye. Since more than one leak can exist, always inspect each component.
1. Check for leaks using a 120 Watt UV spot lamp.
- Scan all components, fittings and lines of the A/C system.
2. After the leak is repaired, remove any traces of tracer dye with a general purpose oil solvent.
3. Verify the repair by operating the system for a short time and inspect with the UV spot lamp.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Capacity ...............................................................................................................................................
............................................................ 266 ml (9 oz)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 8621
Refrigerant Oil: Fluid Type Specifications
PAG Refrigerant Compressor Oil
R-134a Systems ...................................................................................................................
F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
8622
Refrigerant Oil: Service Precautions
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed for new installation, some of the refrigerant oil will go with the component. To maintain the
original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system
with the new part.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
8623
Refrigerant Oil: Service and Repair
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed for new installation, some of the refrigerant oil will go with the component. To maintain the
original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system
with the new part.
1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour
the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a
Systems) or equivalent into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5
ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a
Systems) or equivalent into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces),
pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent
into the new A/C compressor.
NOTE: Service A/C compressors are shipped without compressor oil.
2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier
cylinder and drain the oil into a calibrated container.
- Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml
(2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil
(R-134a Systems) or equivalent to the suction
accumulator/drier inlet tube.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
8624
4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil
(R-134a Systems) or equivalent to the A/C condenser
core or the suction accumulator/drier inlet tube.
5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent
to the suction accumulator/drier inlet tube when
carrying out each of the following repairs: installation of a new A/C evaporator core orifice
- installation of a new A/C compressor pressure relief valve
- installation of a new refrigerant line
- repair of an O-ring seal leak
- repair of a charge port leak
6. Installation of new components that do not require you to Perform the Refrigerant Discharging
and Recovery Procedure of refrigerant and
resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require
additional oil.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Page 8628
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Diagrams > A/C Pressure Switch
A/C High Pressure Switch Connector
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Diagrams > A/C Pressure Switch > Page 8631
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction
accumulator.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction pressure inside the suction accumulator to control the operation of the A/C
cycling switch.
- The electrical switch contacts open when the suction pressure drops, The contacts close when
the suction pressure rises. Refer to specifications regarding operating pressure(s).
- When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the
wide open throttle A/C cutoff relay.
- When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of air flow.
- It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the
A/C cycling switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch > Page 8634
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch
PCM Inputs
AIR CONDITIONING CYCLING SWITCH
The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or
ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will
turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling
switch, refer to Heating and Air Conditioning.
The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when
the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch
and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are
closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle
specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See:
Powertrain Management/Description and Operation/PCM Outputs
NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C
is requested. This information is received by the PCM through the BUS + and BUS - Standard
Corporate Protocol (SCP) communication.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch > Page 8635
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure
Switch
The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure
side of the A/C manifold and tube.
- A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises, the switch contacts open, disengaging the A/C
compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor. Refer to specifications regarding operating pressure(s).
- It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the
A/C pressure cutoff switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations
Blower Motor Relay: Locations
Diagram 700-01-00-1
Diagram 700-01-00-5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 8640
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 8641
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > High Speed Fan Control Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > High Speed Fan Control Relay > Page 8644
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Page 8645
Blower Motor Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Page 8646
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 8650
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 8651
Compressor Clutch Relay: Description and Operation
WIDE OPEN THROTTLE A/C CUT-OFF
The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally
open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)).
If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant
temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C
(WAC) output, closing the relay contacts and sending voltage to the A/C clutch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 8652
Compressor Clutch Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 8653
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips
Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 8658
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 8659
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Service and Repair
Air Conditioning Switch: Service and Repair
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Diagrams
Blower Motor Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Diagrams > Page 8667
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Diagrams > Page 8668
Blower Motor Switch: Description and Operation
Function Selector Switch
The function selector switch combines a vacuum selector valve with two electrical switches to
supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit.
Temperature Control Switch
Temperature selection is accomplished with a potentiometer connected to the electric blend door.
Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a
corresponding movement on the air temperature that the air system will maintain.
Blower Motor Switch
The blower motor switch controls blower motor speed by adding or by passing resistors in the
heater blower motor switch resistor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Diagrams > Page 8669
Blower Motor Switch: Service and Repair
CLIMATE CONTROL ASSEMBLY-FRONT SWITCHES
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
Manual A/C Electrical Components, Part 1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Page 8673
Manual A/C Electrical Components, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Diagrams > A/C Pressure Switch
A/C High Pressure Switch Connector
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Diagrams > A/C Pressure Switch > Page 8676
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction
accumulator.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction pressure inside the suction accumulator to control the operation of the A/C
cycling switch.
- The electrical switch contacts open when the suction pressure drops, The contacts close when
the suction pressure rises. Refer to specifications regarding operating pressure(s).
- When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the
wide open throttle A/C cutoff relay.
- When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of air flow.
- It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the
A/C cycling switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8679
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch
PCM Inputs
AIR CONDITIONING CYCLING SWITCH
The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or
ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will
turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling
switch, refer to Heating and Air Conditioning.
The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when
the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch
and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are
closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle
specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See:
Powertrain Management/Description and Operation/PCM Outputs
NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C
is requested. This information is received by the PCM through the BUS + and BUS - Standard
Corporate Protocol (SCP) communication.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8680
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure
Switch
The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure
side of the A/C manifold and tube.
- A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises, the switch contacts open, disengaging the A/C
compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor. Refer to specifications regarding operating pressure(s).
- It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the
A/C pressure cutoff switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations
Refrigerant System Components
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page
8684
Service Port HVAC: Description and Operation
Service Gauge Port Valve
The high-pressure service gauge port valve is located on the front A/C manifold and tube. The low
pressure service gauge port valve is located on the suction accumulator. The fitting is an integral
part of the refrigeration line or component.
- Special couplings are required for both the high-side and low-side service gauge ports.
- A new Schrader-type valve core can be installed if the seal leaks.
- Always install the A/C charging valve cap on the service gauge port valves after repairing the
refrigerant system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Customer Safety Information
Vacuum Harness HVAC: Customer Safety Information
WARNING:
BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING
METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON
THE PRODUCT LABEL.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Customer Safety Information > Page 8689
Vacuum Harness HVAC: Technician Safety Information
WARNING:
BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING
METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON
THE PRODUCT LABEL.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Page 8690
Vacuum Harness HVAC: Service and Repair
Vacuum Pump Kit
SPECIAL TOOL(S)
1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of
standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch longer than the
damaged area of the mini-tube vacuum
hose).
3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose
ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent
will seal the mini-tube
in the vacuum hose.
WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT
POSSIBLE PERSONAL INJURY .
5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the
standard 1/8 inch repair vacuum hose section. 6. Shake the repair joint after assembly to make
sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum
leak in the repair area.
- Use the Vacuum Tester or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Page 8691
Vacuum Pump Kit
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service
and Repair
Vacuum Reservoir HVAC: Service and Repair
REMOVAL
1. Prepare the vehicle for vacuum reservoir removal.
1 Disconnect the battery ground cable.
2 Remove the air cleaner assembly.
2. Remove the screws. Position the air cleaner housing mounting bracket out of the way. 3. Raise
and support the vehicle.
4. Remove the screws. 5. Lower the vehicle.
6. Label and disconnect the vacuum hoses. Remove the vacuum reservoir.
NOTE: The vacuum hoses to the vacuum reservoir are not interchangeable. Note the location of
each vacuum hose to make sure of correct installation.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment
Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After
A Supplemental Restraint System (SRS) Deployment
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment
WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools
are not removed, the supplemental restraint system (SRS) device may not deploy in a crash.
Failure to follow this instruction may result in serious personal injury or death in a crash and
possibly violate vehicle safety standards.
NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system
diagnostic tools (if required) must be removed before operating the vehicle over the road.
NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in
various combinations depending on the impact event.
NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle
repairs affecting the SRS and safety belt system.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices are deployed and/or the restraints control
module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the
vehicle's SRS is to include the removal of all deployed devices and the installation of new
deployable devices, the removal and installation of new impact sensors, and the removal and
installation of a new RCM. DTCs must cleared from all required modules after repairs are carried
out.
Vehicles with occupant classification sensor (OCS) system
2. NOTE: After installation of new occupant classification sensor (OCS) system components carry
out the OCS System Reset procedure as
instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system
removal and installation procedure.
When a vehicle has been involved in a collision and the occupant classification system module
(OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following
procedures for the specified system:
- For rail type OCS system, inspect the passenger side floorpan for damage and repair as
necessary. Install new OCS system rails.
- For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and
repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be
cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset.
Do not install a new OCSM unless DTC B1231 cannot be cleared.
- NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The
DTC B1231 is stored only by the RCM.
For bladder type OCS system, inspect for damage and repair as necessary. If installation of an
OCS system component is required, an OCS system service kit must be installed.
All vehicles
3. When any damage to the impact sensor mounting points or mounting hardware has occurred,
repair or install new mounting points and mounting
hardware as needed.
4. When the driver air bag module has deployed, a new clockspring must be installed.
5. New driver and/or front passenger safety belt systems (including retractors, buckles and height
adjusters) must be installed if the vehicle is
involved in a collision that results in deployment of the driver and/or front passenger safety belt
pretensioners. For additional information, refer to Safety Belt System.
6. Inspect the entire vehicle for damage, including the following components:
Steering column (deployable column if equipped) Instrument panel knee bolsters and mounting
points Instrument panel braces and brackets Instrument panel and mounting points Seats and seat
mounting points Safety belts, safety belt buckles and safety belt retractors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 8700
SRS wiring, wiring harnesses and connectors
7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 8701
Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After
A Collision
SAFETY BELT PROCEDURE AFTER A COLLISION
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters, child safety seat tether attachments (if
equipped), and attaching hardware should be inspected after any collision. New belt assemblies
should be installed unless a qualified technician finds the assemblies show no damage and operate
correctly. Belt assemblies not in use during a collision should also be inspected and replaced if
either damage or incorrect operation is noted.
NOTE: Safety belt assemblies should be periodically inspected to make sure they have not
become damaged and that they remain in correct operating condition, particularly if they have been
subjected to severe stress.
Before installing the new safety belt assembly, the safety belt attaching areas must be inspected
for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must
be reworked back to its original shape and structural integrity.
Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Seats Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Disconnect the battery ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical
connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air
bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor
connector.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side floor connector. 11. Reconnect the battery ground cable.
Seats Not Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery
ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8707
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate
controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint
system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector
to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector
beneath the front seat.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
passenger side air bag electrical connector beneath
the front seat.
11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat.
12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side air bag electrical connector beneath the
front seat.
13. Reconnect the battery ground cable.
Deactivation Procedure
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will This will
reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8708
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood connected.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8709
8. Remove the driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
11. Open the glove compartment door past its stops to access the mounting screws.
12. Remove the two screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8710
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door. Reaching one hand into the glove
compartment opening push out on the passenger air bag module and separate it from the
instrument panel. Note the wire harness routing for installation.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
Vehicles without seat side air bags
16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag
bridge resistor from the side air bag to floor connector.
If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints
control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor
connector, a low resistance fault will be generated by the RCM.
Vehicles with seat side air bags and power driver seat
17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the battery ground
cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Vehicles with seat side air bags
18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side
air bags and power driver seat
19. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery
ground cable (14301) and wait at least one minute. For additional information, See: Starting and
Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8711
Vehicles with seat side air bags
20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
All vehicles
24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close
the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery
Reactivation Procedure
Reactivation
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8712
1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the
instrument panel, open the kick panel cover and remove the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the wiring Diagram Manual.
3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
Vehicles with seat side air bags
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
Vehicles with seat side air bags and power driver seat
8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8713
Vehicles with seat side air bags
9. Position the front seats rearward.
Vehicles with seat side air bags and power driver seat
10. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air
bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply
energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery
All vehicles
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical
connector.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Position the passenger air bag module into the instrument panel. Route the wire harness as noted
in removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8714
14. Install the two screws.
15. Close the glove compartment door.
16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
17. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to
the steering wheel.
18. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8715
19. Install the two steering wheel back cover plugs.
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear
blower, 15A with rear blower) to the CJB and close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to
OFF. Wait 10 seconds, then turn the key back to
ON and visually monitor the air bag indicator with the air bag modules installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an air bag
supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light.
-remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after
the ignition switch has been turned from the OFF to the ON position. This is the time required for
the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is
inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this
occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
25. Clear all continuous DTCs from the restraints control module using a scan tool.
Procedures For Repair Operations
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8716
accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: .
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8717
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8718
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8719
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8720
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Seats Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic
tool from the driver seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger
seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic
tool from the clockspring connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8721
8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable.
10. Prove out the system.
Seats Not Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring
connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove
the restraint system diagnostic tool from the floor connector beneath the front passenger seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the
passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from
the floor connector beneath the driver seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver
seat.
10. Reconnect the battery ground cable. 11. Prove out the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8722
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 8723
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint
System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System - Air Bag
Lamp ON/DTC B1994/B1998
Air Bag Harness: Customer Interest Restraint System - Air Bag Lamp ON/DTC B1994/B1998
Article No. 03-24-1
12/08/03
ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994
AND/OR B1998
FORD: 1999-2001 EXPLORER SPORT, EXPLORER
MERCURY: 1999-2001 MOUNTAINEER
This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage.
ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit
an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998
stored in memory. This may be due to a high resistance or poor connections in the side air bag
(SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles
equipped with, or without, side air bags.
ACTION To service, install an overlay harness which incorporates soldered terminals and tin
wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation
instructions and illustrations are included in the kit.
SERVICE PROCEDURE
FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z"
1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction
sheet included in the kit.
FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D"
1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet
included in the kit.
^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB
^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC
^ 1999-2000 2DR Explorer XL2Z-14B455-BC
^ 2001 2DR Explorer 1L2Z-14B455-AC
Reference section 501-20A of the appropriate model year Workshop Manual for additional
information if needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System - Air Bag
Lamp ON/DTC B1994/B1998 > Page 8733
Labor Operation Claiming Chart
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-01-10
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B455 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System Air Bag Lamp ON/DTC B1994/B1998
Air Bag Harness: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC
B1994/B1998
Article No. 03-24-1
12/08/03
ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994
AND/OR B1998
FORD: 1999-2001 EXPLORER SPORT, EXPLORER
MERCURY: 1999-2001 MOUNTAINEER
This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage.
ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit
an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998
stored in memory. This may be due to a high resistance or poor connections in the side air bag
(SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles
equipped with, or without, side air bags.
ACTION To service, install an overlay harness which incorporates soldered terminals and tin
wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation
instructions and illustrations are included in the kit.
SERVICE PROCEDURE
FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z"
1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction
sheet included in the kit.
FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D"
1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet
included in the kit.
^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB
^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC
^ 1999-2000 2DR Explorer XL2Z-14B455-BC
^ 2001 2DR Explorer 1L2Z-14B455-AC
Reference section 501-20A of the appropriate model year Workshop Manual for additional
information if needed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System Air Bag Lamp ON/DTC B1994/B1998 > Page 8739
Labor Operation Claiming Chart
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-01-10
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B455 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > Page 8740
Air Bag Harness: Service Precautions
CAUTION:
^ Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat
not secured in the vehicle may result in damaged components.
^ When positioning the seat or separating the seat bottom from the back, be careful not to damage
the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can
cause damage to one of the seat components.
^ Use care when connecting the seat cushion side shield to the seat cushion frame so the tabs on
the seat cushion side shield are not damaged.
^ Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the
side air bag bridge resistor from side air bag floor connector.
If the side air bag bridge resistor is removed, an open circuit fault will be generated by the
Restraints Control Module (RCM).
If a resistance system diagnostic tool installed at the side air bag floor connector, a low resistance
fault will be generated by the RCM.
^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook
and loop strip can be torn from the seat cushion foam.
^ Make sure the side air bag wiring harness is not pinched between the side air bag module and
the mounting bracket.
^ The retaining nuts of the side air bag module must be tightened in the sequence described.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal
Air Bag Harness: Service and Repair Removal
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8743
removed from the vehicle and the restraint system diagnostic tools must be installed in the side
airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The
restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8744
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
8. Using the special tool, remove the safety belt buckle support bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8745
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8746
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8747
21. Disconnect the clockspring electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery
ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR
BAGS CANNOT BE REPAIRED. NEW TRIM COVERS MUST BE INSTALLED (CLEANING IS
PERMISSIBLE).
26. Disconnect the seat motor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8748
27. Remove the four bolts and the seat track from the seat bottom.
28. Disconnect the power seat switch electrical connector. 29. Turn the manual lumbar handle
clockwise until it stops, releasing all tension on the manual lumbar support cable.
30. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim
panel retaining screw.
31. Remove the lower seat trim panel screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8749
32. Remove the lower seat trim panel.
1 Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel
from the seat bottom frame.
2 Remove the lower seat trim panel.
33. Remove the push pin holder from the seat bottom frame for the lumbar support cable.
NOTE: Install a new pin-type retainer, if damaged.
34. Separate the lumbar support cable assembly.
1 Separate the lumbar support case assembly by sliding apart.
2 Remove the cable end ball from the cable end retainer and separate.
35. Separate the side air bag electrical connector and wire harness from the seat bottom frame.
1 Release the finger clip and slide the side air bag electrical connector from the bracket.
2 Separate the side air bag wire harness pin-type retainer from the seat bottom frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8750
NOTE: Install new pin-type retainers, if damaged.
36. Remove the bolts.
37. Laying the seat on its other side, remove the retaining bolt from the seat pivot.
CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
38. Remove the seatback from the seat bottom.
1 While noting the routing, pull the lumbar support cable through the seat bottom.
2 While noting the routing, pull the side air bag module wire harness through the seat bottom.
3 Remove the seat back from the seat bottom.
39. Separate the seat back trim cover lower J-clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8751
40. Remove and discard the hog rings from the two swing rods (one shown).
41. Slide the swing rods out of the seat back trim cover.
42. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The
hook and loop strip can be torn from the seat cushion foam.
43. Remove and discard the tie-strap holding the deployment chute tail and side air bag wire
harness in place.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8752
44. Unzip the side air bag deployment chute.
45. Roll the seat back cover and side air bag deployment chute to completely expose the side air
bag module, mounting bracket and side air bag shield.
46. Remove and discard the duct tape retaining the side air bag shield.
47. Separate the side air bag wiring harness pin-type retainers from the seat back frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8753
48. Remove the side air bag stud covers.
49. Remove the side air bag module nuts.
NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag
module is to be reused, then reuse the side air bag module retaining nuts.
50. Position the side air bag module and shield out through the seat back cushion opening.
51. Remove the side air bag module.
1 Slide the side air bag module electrical connector locking clip to disengage it.
2 Release the connector tabs by pushing in on them, then disconnect the side air bag module
electrical connector.
3 Remove the side air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8754
52. Remove the shield from the side air bag module. 53. Remove the side air bag wire harness
from the seat backrest frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8755
Air Bag Harness: Service and Repair Installation
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the side air bag wire harness to the seat backrest frame.
2. Install the shield onto the side air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8756
3. Connect the side air bag module electrical connector.
1 Install the connector to the side air bag module.
2 Slide the side air bag module electrical connector locking clip to secure the connector to the side
air bag module.
4. Make sure the electrical connector is securely fastened to the side air bag module.
5. Position the side air bag module and shield into the seat backrest cushion.
WARNING: ^
INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT
BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING
THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG
DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN
THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE
FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE
EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN
EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR
BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF
AN AIR BAG DEPLOYMENT.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED AS A UNIT.
6. Position the side air bag module studs, with the shield still in place, through the scat backrest
mounting bracket holes.
^ Do not pinch the side air bag module wiring harness between the side air bag module and the
mounting bracket.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8757
CAUTION: Make sure the side air bag wiring harness is not pinched between the side air bag
module and the mounting bracket.
7. Route the side air bag module wire harness and install the side air bag nuts and tighten in the
sequence shown.
1 Route the side air bag module wire harness to the back side of the side air bag mounting bracket
making sure it is not pinched between the side air bag module and the mounting bracket.
2 Install the side air bag nut.
3 Install the side air bag nut.
4 Install the side air bag nut.
CAUTION: ^
The retaining nuts of the side air bag module must be tightened in the sequence described.
^ Make sure the side air bag wiring harness is not pinched between the side air bag module and
the mounting bracket.
8. Install the side air bag stud covers.
9. Position the side air bag shield to the seat backrest frame.
1 Apply new duct tape to the side air bag shield.
2 Position the side air bag module wire harness so that it will fit loosely between the side air bag
shield and the mounting bracket.
3 Position the side air bag shield to the seat backrest frame keeping it in place with the tape. ^
Check that the side air bag module wire harness fits loosely between the side air bag shield and
the mounting bracket and is not pinched.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8758
10. Route the side air bag wire harness and install the pin-type retainers to the seat back frame.
11. Unroll the seat back trim cover to position the deployment chute around the side air bag
module.
12. Position the air bag deployment chute.
1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side
air bag module, pulling it around the outboard side of the seat back frame.
2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side
air bag module from the inboard side of the seat back.
WARNING: ^
CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED AS A UNIT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8759
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.
13. Zip the air bag deployment chute completely closed, then position the zipper tail at the top of
the deployment chute, into the seat back opening.
^ The side air bag deployment chute must encircle the side air bag module, going completely
around the side air bag module and the side of the seat back frame.
^ Align the side air bag deployment chute to the side air bag module, making sure it covers the
length of the side air bag module.
NOTE: Be sure the side air bag deployment chute is properly positioned, before proceeding.
14. Position the deployment chute tail and side air bag wire harness and tie-strap them in place.
15. Unroll the seat back trim cover to the bottom row of hog rings.
16. Install the swing rods back into the seat back trim cover sleeves.
17. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog
rings, position the top of the swing rods under the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8760
listing wire in the seat back pad.
NOTE: The seat back trim cover has been inverted for clarity.
18. Install new hog rings onto the swing rods (one shown). 19. Pull the seat backrest trim cover
completely down and connect the hook and loop fastener to the seat back cushion.
20. Reattach the seat back trim cover lower J-clips.
21. Position the seat back to the seat bottom and route the wires and cables.
1 Position the seat back to the seat bottom.
2 Pull the side air bag module wire harness through the seat bottom.
3 Pull the lumbar support cable through the seat bottom.
22. Align the seat back to the seat bottom. Install the bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8761
CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
23. Install the bolts.
CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
24. Route the side air bag module wire harness.
1 Slide the side air bag wire harness onto the finger clip.
2 Install the side air bag wire harness pin-type retainer into the seat bottom frame.
25. Connect the lumbar support cable assembly.
1 Install the cable end ball to the cable end retainer.
2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8762
26. Install the push pin holder to the seat bottom frame and insert the lumbar support cable.
27. Install the seat bottom lower side shield into the seat bottom frame.
1 Align the seat bottom lower side shield retaining clips to the seat bottom.
2 Push in on the lower side shield, seating the clips (one shown) into the seat bottom frame.
28. Install the lower side shield screw.
29. Install the lower side shield retaining screw and the lumbar support handle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8763
30. Connect the power seat switch electrical connector.
31. Position the seat track to the seat bottom frame. Install the four bolts and tighten to
specification.
32. Connect the seat motor electrical connector. 33. Position the driver seat into the vehicle. Install
and hand-tighten the four seat track to floor bolts.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
34. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8764
35. Connect the driver seat side air bag and power seat electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
3 Tie-strap the wire harness.
36. Connect the battery ground cable. 37. Position the driver seat rearward. 38. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
39. Tighten the driver seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
40. Move and tilt the driver seat to its highest and most forward position. 41. Tighten the driver seat
rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8765
42. Install the driver seat rear track bolt covers.
43. Connect the safety belt warning indicator electrical connector.
44. Using the special tool, install the safety belt buckle support bolt.
45. Install the safety belt buckle support bolt cover. 46. Position the driver seat rearward. 47.
Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8766
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
48. Position the passenger seat forward.
49. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
50. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 51.
Position the passenger seat rearward.
52. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
53. Install the passenger air bag module.
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Service and Repair > Removal > Page 8767
54. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
55. Connect the clockspring electrical connector at the base of the steering column.
56. Position the lower steering column opening finish panel reinforcement and install the bolts.
57. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Service and Repair > Removal > Page 8768
58. Position the hood release handle and install the screws. 59. Connect the battery ground cable.
60. With all the diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
61. Check the restraint system for correct operation.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8773
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8774
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8775
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8776
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8777
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8778
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8779
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 8780
Air Bag Control Module: Specifications
Restraints Control Module Bolts 12 Nm
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 8781
Air Bag Control Module: Locations
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
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Technical Service Bulletins > Page 8782
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 8783
Air Bag Control Module: Diagrams
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Technical Service Bulletins > Page 8784
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Technician Safety Information
Air Bag Control Module: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Technician Safety Information > Page 8787
Air Bag Control Module: Vehicle Damage Warnings
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Page 8788
Air Bag Control Module: Description and Operation
The Restraints Control Module (RCM) carries out the following functions:
^ signals the inflators to deploy the air bags in the event of a deployable crash.
^ monitors the air bag supplemental restraint system (SRS) for faults.
^ illuminates the air bag indicator if a fault is detected.
^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic
Trouble Codes (DTCs).
^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safing sensor is internal to the RCM and is not serviced separately.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the RUN position, the RCM will flash the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the
LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also
communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag
indicator does not function, and the system detects a fault condition, the RCM will signal the GEM
to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is
heard, the SRS and the air bag indicator require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors determine that a deployment is required. The backup power supply will deplete its
stored energy approximately one minute after the battery ground cable is disconnected.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Page 8789
Air Bag Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Air Bag Systems; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module
Air Bag Control Module: Service and Repair Restraints Control Module
With Side Air Bags
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8792
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8793
4. Remove the retaining bolts and remove the lower steering column opening finish panel
reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8794
SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR
STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS
DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD
LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8795
15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18.
Reconnect the battery ground cable. 19. With the restraint system diagnostic tools installed at all
deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 20.
Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
21. Remove the full floor console.
Vehicles with a restraint control module cover
22. Remove the mat, the screws and the Restraint Control Module (RCM) cover.
23. Remove the right-hand side RCM retaining bolts
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8796
24. Remove the RCM.
1 Slide and disengage the two RCM electrical connector locking clips.
2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect.
3 Remove the retaining bolt.
4 Remove the RCM.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Position the RCM to the center tunnel area and install the three bolts hand-tight.
WARNING: ^
THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and
safety belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8797
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Tighten the right-hand side RCM bolts to specification.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Connect the RCM.
1 Tighten the bolt to specification.
2 Connect the RCM electrical connectors.
3 Slide and engage the RCM electrical connector locking clips.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all
deployable devices, prove out the air bag system.
6. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8798
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
7. Install the full floor console.
Vehicles with a restraint control module cover
8. Position the RCM cover. Install the screws and the mat.
9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
10. Connect the clockspring electrical connector at the base of the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8799
11. Position the lower steering column opening finish panel reinforcement and install the bolts.
12. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top seating
the retaining clips.
2 Install the screws.
13. Position the hood release handle and install the screws.
14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8800
15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. Move and tilt
the front seats to their highest and most forward position. 18. Disconnect the battery ground cable
and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
19. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
21. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8801
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
22. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 23.
Connect the battery ground cable. 24. Position the front seats rearward. 25. Connect the battery
ground cable. 26. With all the diagnostic tools removed, prove out the air bag system. See: Air
Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Without Side Air Bags
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8802
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8803
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
4. Remove the retaining bolts and remove the lower steering column opening finish panel
reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8804
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Reconnect the battery ground cable.
10. With the restraint system diagnostic tools installed at all deployable devices, prove out the air
bag system. See: Air Bag(s) Arming and Disarming 11. Disconnect the battery ground cable and
wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
12. Remove the full floor console.
Vehicles with a restraint control module cover
13. Remove the mat, the screws and the Restraint Control Module (RCM) cover.
14. Remove the right-hand side RCM retaining bolts
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8805
15. Remove the RCM.
1 Slide and disengage the two RCM electrical connector locking clips.
2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect.
3 Remove the retaining bolt.
4 Remove the RCM.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Position the RCM to the center tunnel area and install the three bolts hand-tight.
WARNING: ^
THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and
safety belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8806
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Tighten the right-hand side RCM bolts to specification.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Connect the RCM.
1 Tighten the bolt to specification.
2 Connect the RCM electrical connectors.
3 Slide and engage the RCM electrical connector locking clips.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
4. Connect the battery ground cable.
5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air
bag system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8807
6. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
7. Install the full floor console.
Vehicles with a restraint control module cover
8. Position the RCM cover. Install the screws and the mat.
9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8808
10. Connect the clockspring electrical connector at the base of the steering column.
11. Position the lower steering column opening finish panel reinforcement and install the bolts.
12. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top seating
the retaining clips.
2 Install the screws.
13. Position the hood release handle and install the screws.
14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8809
VEHICLE SAFETY STANDARDS.
15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. With all the
diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8810
Air Bag Control Module: Service and Repair Weld Nut Repair
"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control
Module (RCM) and Side Crash Sensor before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut
Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts
must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and
Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification. Refer to Torque Specifications.
Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM)
and Side Crash Sensor before proceeding with the repair.
^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld
Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-S190).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Restraints Control Module > Page 8811
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification. Refer to Torque Specifications.
Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE
LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Refer to Torque Specifications.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Page 8812
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Locations
Air Bag Resistor: Locations
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Locations
> Page 8816
Air Bag Resistor: Service Precautions
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
and Repair > Driver Side
Air Bag Resistor: Service and Repair Driver Side
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Move and tilt the driver seat to its highest and most forward position. 2. Disconnect the battery
ground cable and wait atleast one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
3. Disconnect the driver seat side air bag delete resistor electrical connector.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag delete resistor electrical connector.
4. Remove the driver seat side air bag delete resistor.
1 Push up to release the finger clip.
2 Slide the driver seat side air bag delete resistor off the finger clip.
INSTALLATION
WARNING:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
and Repair > Driver Side > Page 8819
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Slide the driver seat side air bag delete resistor onto the finger clip.
2. Connect the driver seat side air bag delete resistor.
1 Connect the driver seat side air bag delete resistor.
2 Tie-strap the wire harness in place.
3. Connect the battery ground cable. 4. Prove out the air bag system. See: Air Bag(s) Arming and
Disarming
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
and Repair > Driver Side > Page 8820
Air Bag Resistor: Service and Repair Passenger Side
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Move the passenger seat to its most forward position.
3. Disconnect the passenger seat side air bag delete resistor electrical connector.
1 Remove the tie-strap.
2 Disconnect the passenger seat side air bag delete resistor electrical connector.
4. Remove the passenger seat side air bag delete resistor.
1 Push up to release the finger clip.
2 Slide the passenger seat side air bag delete resistor off the finger clip.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
and Repair > Driver Side > Page 8821
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Slide the passenger seat side air bag delete resistor onto the finger clip.
2. Connect the passenger seat side air bag delete resistor.
1 Connect the passenger seat side air bag delete resistor.
2 Tie-strap the wire harness in place.
3. Connect the battery ground cable. 4. Prove out the air bag system. See: Air Bag(s) Arming and
Disarming
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications
Clockspring Assembly / Spiral Cable: Specifications
Lower Steering Column Opening Finish Panel Reinforcement Bolts
.......................................................................................................... 12 N.m (9 Lb-Ft) Lower
Steering Column Opening Finish Panel Screws
.............................................................................................................................. 3 N.m (27 Lb-In)
Hood Release Handle Screws .............................................................................................................
......................................................... 3 N.m (27 Lb-In) Steering Column Fore And Aft Nuts
......................................................................................................................................................... 15
N.m (11 Lb-Ft)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 8825
Clockspring Assembly / Spiral Cable: Locations
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 8826
Clockspring Assembly / Spiral Cable: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Technician Safety Information
Clockspring Assembly / Spiral Cable: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ INCORRECT CENTRALIZATION MAY RESULT IN PREMATURE COMPONENT FAILURE. IF
IN DOUBT WHEN CENTRALIZING THE CLOCKSPRING, REPEAT THE CENTRALIZING
PROCEDURE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL
INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Technician Safety Information > Page 8829
Clockspring Assembly / Spiral Cable: Vehicle Damage Warnings
CAUTION:
^ Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be
broken from its internal connection.
^ Make sure the road wheels are in the straight-ahead position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8830
Clockspring Assembly / Spiral Cable: Description and Operation
The clockspring:
^ is mounted on the steering column, behind the steering wheel.
^ provides a continuous electrical path between the Restraints Control Module (RCM) and the
driver air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags
Clockspring Assembly / Spiral Cable: Service and Repair With Side Air Bags
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8833
procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
4. Remove the bolts and the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8834
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the base of the steering column. 7. Remove the passenger air bag module.
8. Attach the restraint system diagnostic to the vehicle harness side of the passenger air bag
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8835
12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18.
Connect the battery ground cable. 19. With the restraint system diagnostic tools installed at all
deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 20.
Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8836
SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR
STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS
DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD
LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
21. Remove the two steering wheel back cover plugs.
22. Remove the two driver air bag module retaining bolts.
23. Remove the driver air bag module.
1 Disconnect the driver air bag module electrical connector.
2 Remove the driver air bag module.
24. Remove the steering wheel.
NOTE: Make sure the wheels are in the straight-ahead position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8837
25. Loosen, but do not remove, the four steering column-to-instrument panel retaining bolts enough
to remove the upper steering column shroud (two
shown).
Vehicles with tilt column
26. Remove the tilt wheel handle shank.
27. Remove the lower steering column shroud.
1 Remove the three screws.
2 Remove the lower steering column shroud.
28. Remove the ignition switch lock cylinder.
1 Position the ignition switch lock cylinder to the RUN position.
2 Using the suitable tool, push upward on the cylinder release tab while pulling the ignition switch
lock cylinder outward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8838
29. Remove the upper steering column shroud.
30. Remove the Passive Anti-theft System (PATS) transmitter.
1 Remove the PATS transmitter retaining screw.
2 Position the PATS transmitter out of the way.
31. Remove the key-in-ignition warning indicator switch.
32. Disconnect the clockspring electrical connectors.
1 Remove the bolt and separate the ground wire.
2 Remove the clockspring electrical connectors from the instrument panel and disconnect the
remaining clockspring electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8839
33. Remove the clockspring wire harness from the two holders.
34. Release the lower clockspring retaining clip.
35. Remove the clockspring.
1 Release the remaining two clockspring retaining clips.
2 Remove the clockspring.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8840
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
Vehicles receiving a new clockspring
1. Remove the key from the clockspring, holding then rotor in its centralized position.
^ Do not allow the clockspring rotor to turn.
NOTE: A new clockspring is supplied in a centralized position and held there with a key.
Vehicles needing clockspring recentering
2. Centralize the clockspring.
1 Hold the clockspring outer housing stationary.
2 Depress the clockspring locking tab to release the rotor.
3 While holding the clockspring locking tab into the released position, turn the rotor
counterclockwise, carefully feeling for the ribbon wire to run out of length, and a slight resistance is
felt. Stop turning at this point.
CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and
can be broken from its internal connection.
4 While holding the clockspring locking tab in the released position, turn the rotor clockwise
approximately 3 turns. This is the center point of
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8841
the clockspring. ^
Release the clockspring locking tab. Lock the rotor in the centralized position.
WARNING: INCORRECT CENTRALIZATION MAY RESULT IN PREMATURE COMPONENT
FAILURE. IF IN DOUBT WHEN CENTRALIZING THE CLOCKSPRING, REPEAT THE
CENTRALIZING PROCEDURE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN
PERSONAL INJURY.
CAUTION: Make sure the road wheels are in the straight-ahead position.
NOTE: If a clockspring has rotated out of center, follow through with this step.
3. Position the clockspring onto the steering column shaft.
1 Align the clockspring onto the steering column shaft.
2 Slide the clockspring down the steering column shaft and lock the clips into place.
4. Engage the lower clockspring retaining clip into place.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8842
5. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
6. Connect the clockspring electrical connectors.
1 Connect the two clockspring electrical connectors to the vehicle harness and install the electrical
connector pin-type retainers to the bracket.
2 Position the ground wire and install the bolt.
7. Route the wire harness into the two holders.
8. Install the key-in-ignition warning indicator switch to the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8843
9. Install the passive anti-theft system (PATS) transmitter.
1 Position the PATS transmitter to the steering column.
2 Install the PATS transmitter retaining screw.
10. Position the upper steering column shroud to the steering column.
11. Install the lower steering column shroud.
1 Position the lower steering column shroud to the steering column and the upper steering column
shroud.
2 Install the screws.
12. Tighten the four steering column to instrument panel retaining bolts (two shown).
Vehicles with tilt column
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8844
13. If equipped, install the tilt wheel handle and shank.
14. Install the ignition switch lock cylinder.
^ Align and install the ignition switch lock cylinder to the steering column. ^
Position the ignition switch lock cylinder to the off position.
15. Install the steering wheel.
NOTE: Make sure the wheels are in the straight-ahead position.
16. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of
the steering column. 17. Connect the battery ground cable. 18. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 19. Disconnect the battery
ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8845
20. Position the lower steering column opening finish panel reinforcement and install the bolts.
21. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
22. Position the hood release handle and install the screws.
23. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top
of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8846
24. Position the driver air bag module to the steering wheel.
1 Connect the driver air bag module electrical connector.
2 Position the driver air bag module to the steering wheel.
25. Install the two driver air bag module retaining bolts.
26. Install the two steering wheel back cover plugs.
27. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
28. Install the passenger air bag module. 29. Connect the battery ground cable. 30. Move and tilt
the front seats to their highest and most forward position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8847
31. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
32. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
33. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
34. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8848
35. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 36.
Connect the battery ground cable. 37. Position the front seats rearward. 38. Connect the battery
ground cable. 39. With all the restraint system diagnostic tools removed, prove out the air bag
system. See: Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8849
Clockspring Assembly / Spiral Cable: Service and Repair Without Side Air Bags
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8850
procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
4. Remove the bolts and the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8851
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the base of the steering column. 7. Remove the passenger air bag module.
8. Attach the restraint system diagnostic to the vehicle harness side of the passenger air bag
electrical connector. 9. Connect the battery ground cable.
10. With the restraint system diagnostic tools installed at all deployable devices, prove out the air
bag system. See: Air Bag(s) Arming and Disarming 11. Disconnect the battery ground cable and
wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8852
12. Remove the two steering wheel back cover plugs.
13. Remove the two driver air bag module retaining bolts.
14. Remove the driver air bag module.
1 Disconnect the driver air bag module electrical connector.
2 Remove the driver air bag module.
15. Remove the steering wheel.
NOTE: Make sure the wheels are in the straight-ahead position.
16. Loosen, but do not remove, the four steering column-to-instrument panel retaining bolts enough
to remove the upper steering column shroud (two
shown).
Vehicles with tilt column
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8853
17. Remove the tilt wheel handle shank.
18. Remove the lower steering column shroud.
1 Remove the three screws.
2 Remove the lower steering column shroud.
19. Remove the ignition switch lock cylinder.
1 Position the ignition switch lock cylinder to the RUN position.
2 Using the suitable tool, push upward on the cylinder release tab while pulling the ignition switch
lock cylinder outward.
20. Remove the upper steering column shroud.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8854
21. Remove the Passive Anti-theft System (PATS) transmitter.
1 Remove the PATS transmitter retaining screw.
2 Position the PATS transmitter out of the way.
22. Remove the key-in-ignition warning indicator switch.
23. Disconnect the clockspring electrical connectors.
1 Remove the bolt and separate the ground wire.
2 Remove the clockspring electrical connectors from the instrument panel and disconnect the
remaining clockspring electrical connector.
24. Remove the clockspring wire harness from the two holders.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8855
25. Release the lower clockspring retaining clip.
26. Remove the clockspring.
1 Release the remaining two clockspring retaining clips.
2 Remove the clockspring.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8856
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION,
INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION.
REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR
BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
Vehicles receiving a new clockspring
1. Remove the key from the clockspring, holding then rotor in its centralized position.
^ Do not allow the clockspring rotor to turn.
NOTE: A new clockspring is supplied in a centralized position and held there with a key.
Vehicles needing clockspring recentering
2. Centralize the clockspring.
1 Hold the clockspring outer housing stationary.
2 Depress the clockspring locking tab to release the rotor.
3 While holding the clockspring locking tab into the released position, turn the rotor
counterclockwise, carefully feeling for the ribbon wire to run out of length, and a slight resistance is
felt. Stop turning at this point.
CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and
can be broken from its internal connection.
4 While holding the clockspring locking tab in the released position, turn the rotor clockwise
approximately 3 turns. This is the center point of the clockspring. ^
Release the clockspring locking tab. Lock the rotor in the centralized position.
WARNING: INCORRECT CENTRALIZATION MAY RESULT IN PREMATURE COMPONENT
FAILURE. IF IN DOUBT WHEN CENTRALIZING THE CLOCKSPRING, REPEAT THE
CENTRALIZING PROCEDURE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN
PERSONAL INJURY.
CAUTION: Make sure the road wheels are in the straight-ahead position.
NOTE: If a clockspring has rotated out of center, follow through with this step.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8857
3. Position the clockspring onto the steering column shaft.
1 Align the clockspring onto the steering column shaft.
2 Slide the clockspring down the steering column shaft and lock the clips into place.
4. Engage the lower clockspring retaining clip into place.
5. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8858
6. Connect the clockspring electrical connectors.
1 Connect the two clockspring electrical connectors to the vehicle harness and install the electrical
connector pin-type retainers to the bracket.
2 Position the ground wire and install the bolt.
7. Route the wire harness into the two holders.
8. Install the key-in-ignition warning indicator switch to the steering column.
9. Install the passive anti-theft system (PATS) transmitter.
1 Position the PATS transmitter to the steering column.
2 Install the PATS transmitter retaining screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8859
10. Position the upper steering column shroud to the steering column.
11. Install the lower steering column shroud.
1 Position the lower steering column shroud to the steering column and the upper steering column
shroud.
2 Install the screws.
12. Tighten the four steering column to instrument panel retaining bolts (two shown).
Vehicles with tilt column
13. If equipped, install the tilt wheel handle and shank.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8860
14. Install the ignition switch lock cylinder.
^ Align and install the ignition switch lock cylinder to the steering column. ^
Position the ignition switch lock cylinder to the off position.
15. Install the steering wheel.
NOTE: Make sure the wheels are in the straight-ahead position.
16. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of
the steering column. 17. Connect the battery ground cable. 18. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 19. Disconnect the battery
ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
20. Position the lower steering column opening finish panel reinforcement and install the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8861
21. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
22. Position the hood release handle and install the screws.
23. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top
of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
24. Position the driver air bag module to the steering wheel.
1 Connect the driver air bag module electrical connector.
2 Position the driver air bag module to the steering wheel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > With Side Air Bags > Page 8862
25. Install the two driver air bag module retaining bolts.
26. Install the two steering wheel back cover plugs.
27. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
28. Install the passenger air bag module. 29. Connect the battery ground cable. 30. With all the
restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming
and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Page 8863
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Specifications
Impact Sensor: Specifications
Side Crash Sensor Bolts 12 Nm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Locations Views
Impact Sensor: Locations Locations Views
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Locations Views > Page 8869
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Locations Views > Page 8870
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Right
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Right > Page 8873
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR
CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN
WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND
BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER
OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE
RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Customer Safety Information > Page 8876
Impact Sensor: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS
CRITICAL FOR PROPER SYSTEM OPERATION.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Page 8877
Impact Sensor: Description and Operation
WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR
CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN
WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND
BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER
OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE
RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
The SRS contains two sensors which are integral to the RCM. The RCM is mounted on the center
tunnel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation
Impact Sensor: Service and Repair Removal and Installation
Side Crash Sensor, Driver Side
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8880
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8881
4. Remove the bolts and the lower steering column opening finish panel reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8882
SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR
STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS
DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD
LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8883
15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the
diagnostic tools in place at all deployable devices, prove out the air bag system. See: Air Bag(s)
Arming and Disarming 19. Position the front seats to their most forward position. 20. Disconnect
the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
21. Pull to release the retaining clips and remove the windshield side garnish molding.
22. Pull up to release the retaining clips and remove the front door scuff plate.
23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8884
24. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26.
Position the carpet aside at the front safety belt anchor.
27. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
28. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8885
3 Remove the quarter trim panel front screw.
29. Fold the rear seat into the load floor position.
30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
31. Remove the retractable cargo cover.
All Vehicles
32. Remove the rear safety belt guide.
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
3 Remove the rear safety belt guide.
33. Position the carpet aside at the rear safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8886
34. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
35. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
36. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
37. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8887
38. Remove the pin-type retainers from the quarter trim panel.
39. Slide the quarter trim panel forward and disengage it from the door jamb.
40. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness
out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8888
42. Position the side crash sensor with bracket away from the B-pillar.
1 Remove the bolts.
2 Position the side crash sensor with bracket away from the B-pillar.
43. Remove the side crash sensor.
1 Disconnect the electrical connector.
2 Remove the side crash sensor.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8889
removed from the vehicle and the restraint system diagnostic tools must be installed in the side
airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The
restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Connect the side crash sensor electrical connector.
1 Position the side crash sensor.
2 Connect the side crash sensor electrical connector.
2. Install the side crash sensor.
1 Position the side crash sensor with the bracket to the B-pillar.
2 Install the bolts.
WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery
ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all
deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest
and most forward position. 8. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8890
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
9. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbings through the openings in the quarter trim panel.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
10. Slide back and engage the edge of the quarter trim panel into the door jamb.
11. Install the quarter trim panel rear screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8891
12. Through the front door opening, install the quarter trim panel front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim panel front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
13. Install the pin-type retainers into the quarter trim panel.
14. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
15. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Vehicles with a rear power lock switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8892
16. Connect and install the rear power lock switch assembly into the rear quarter trim panel.
All vehicles
17. Position the washer on the rear safety belt guide bolt.
18. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
19. Fold the rear seat into the load floor position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8893
20. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
21. Reposition the carpet back over the floor.
22. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo covers
23. Install the retractable cargo cover.
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8894
24. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
25. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
26. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
27. Reposition the carpet at the front safety belt anchor.
28. Align the retaining clips and install the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8895
29. Align the retaining clips and install the windshield side garnish molding. 30. Reposition the rear
seat back upward.
31. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
32. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
33. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8896
VEHICLE SAFETY STANDARDS.
34. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 35.
Connect the battery ground cable. 36. Position the front seats rearward. 37. Disconnect the battery
ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
38. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
39. Install the passenger air bag module.
40. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8897
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
41. Connect the clockspring electrical connector at the base of the steering column.
42. Position the lower steering column opening finish panel reinforcement and install the bolts.
43. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
44. Position the hood release handle and install the screws. 45. Connect the battery ground cable.
46. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and
Disarming
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8898
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
47. Check the restraint system for correct operation.
Side Crash Sensor, Passenger Side
Special Tool(s)
SPECIAL SERVICE TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8899
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All Vehicles
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the passenger air bag module.
3. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
4. Remove the retaining screws and position the hood release handle out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8900
5. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
6. Remove the bolts and the lower steering column opening finish panel reinforcement.
7. Disconnect the clockspring electrical connector at the base of the steering column.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8901
DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING,
REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR
BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES,
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8902
15. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the
diagnostic tools in place at all deployable devices, prove out the air bag system. See: Air Bag(s)
Arming and Disarming 19. Position the front seats to their most forward position. 20. Disconnect
the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
21. Pull to release the retaining clips and remove the windshield side garnish molding.
22. Pull up to release the retaining clips and remove the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8903
23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
24. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26.
Position the carpet aside at the front safety belt anchor.
27. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8904
28. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
3 Remove the quarter trim panel front screw.
29. Fold the rear seat into the load floor position.
30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
31. Remove the retractable cargo cover.
All Vehicles
32. Remove the rear safety belt guide.
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8905
3 Remove the rear safety belt guide.
33. Position the carpet aside at the rear safety belt anchor.
34. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
35. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
36. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
37. Remove the coat hook.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8906
1 Remove the screw.
2 Remove the coat hook.
38. Remove the pin-type retainers from the quarter trim panel.
39. Slide the quarter trim panel forward and disengage it from the door jamb.
40. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness
out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8907
42. Position the side crash sensor with the bracket away from the B-pillar.
1. Remove the bolts. 2. Position the side crash sensor with the bracket away from the B-pillar.
43. Remove the side crash sensor.
1 Disconnect the electrical connector.
2 Remove the side crash sensor.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM(SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8908
removed from the vehicle and the restraint system diagnostic tools must be installed in the side
airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The
restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Connect the side crash sensor electrical connector.
1 Position the side crash sensor.
2 Connect the side crash sensor electrical connector.
2. Install the side crash sensor.
1 Position the side crash sensor with the bracket to the B-pillar.
2 Install the bolts.
WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery
ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all
deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest
and most forward position. 8. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8909
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS. NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
9. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbing through the openings in the quarter trim panel.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
10. Slide back and engage the edge of the quarter trim panel into the door jamb.
11. Install the quarter trim panel rear screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8910
12. Through the front door opening, install the quarter trim panel front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim panel front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
13. Install the pin-type retainers into the quarter trim panel.
14. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
15. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8911
16. Position the washer on the rear safety belt guide bolt.
17. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
18. Fold the rear seat into the load floor position.
19. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
20. Reposition the carpet back over the floor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8912
21. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo covers
22. Install the retractable cargo cover.
All Vehicles
23. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
24. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8913
^ Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
25. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
26. Reposition the carpet at the front safety belt anchor.
27. Align the retaining clips and install the front door scuff plate.
28. Align the retaining clips and install the windshield side garnish molding. 29. Reposition the rear
seat back upward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8914
30. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
31. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
32. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
33. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8915
34. Connect the battery ground cable. 35. Position the front seats rearward. 36. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
37. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
38. Connect the clockspring electrical connector at the base of the steering column.
39. Position the lower steering column opening finish panel reinforcement and install the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8916
40. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
41. Position the hood release handle and install the screws.
42. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
43. Install the passenger air bag module. 44. Connect the battery ground cable. 45. With all the
diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
46. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8917
Impact Sensor: Service and Repair General Procedures
"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control
Module (RCM) and Side Crash Sensor before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut
Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts
must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and
Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification. Refer to Torque Specifications.
Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM)
and Side Crash Sensor before proceeding with the repair.
^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld
Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-S190).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8918
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification. Refer to Torque Specifications.
Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE
LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Refer to Torque Specifications.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Page 8919
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information >
Description and Operation
Safing Sensor: Description and Operation
The safing sensor is internal to the RCM and is not serviced separately.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations >
Locations Views
Side Air Bag: Locations Locations Views
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations >
Locations Views > Page 8927
Side Air Bag: Locations Side Air Bag Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations >
Locations Views > Page 8928
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service
Precautions > Technician Safety Information
Side Air Bag: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE. SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH A SIDE AIR
BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE).
^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT
BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING
THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG
DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN
THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE
FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE
EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN
EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR
BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF
AN AIR BAG DEPLOYMENT.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT
IN PERSONAL INJURY.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service
Precautions > Technician Safety Information > Page 8931
Side Air Bag: Vehicle Damage Warnings
CAUTION:
^ Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat
not secured in the vehicle may result in damaged components.
^ When positioning the seat or separating the seat bottom from the back, be careful not to damage
the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can
cause damage to one of the seat components.
^ Make sure the side air bag wiring harness is not pinched between the side air bag module and
the mounting bracket.
^ The retaining nuts of the side air bag module must be tightened in the sequence described.
^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook
and loop strip can be torn from the seat cushion foam.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service
Precautions > Page 8932
Side Air Bag: Description and Operation
Driver Side Air bag Module
NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel
or instrument panel mounted air bag components of the Supplemental Restraint System (SRS).
The driver side air bag module: ^
has no separately repairable parts and is installed as an assembly.
^ is mounted in the driver seat back.
Passenger Side Air Bag Module
NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel
or instrument panel mounted air bag components of the supplemental restraint system (SRS).
The passenger side air bag module: ^
has no separately repairable parts and is installed as an assembly.
^ is mounted in the passenger seat back.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side
Side Air Bag: Service and Repair Driver Side
Removal
Special Tool(s)
SPECIAL TOOL(S)
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE. SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8935
vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt
pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint
system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if
equipped) connectors at the floor connectors. The restraint system diagnostic tools must be
removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ When replacing the side air bag after deployment.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8936
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support assembly.
8. Using the special tool, remove the safety belt buckle support assembly bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8937
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8938
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8939
21. Disconnect the clockspring electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and
Disarming 25. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
26. Disconnect the seat motor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8940
27. Remove the four bolts and the seat track from the seat bottom.
28. Disconnect the power seat switch electrical connector. 29. Turn the manual lumbar handle
clockwise until it stops, releasing all tension on the manual lumbar support cable.
30. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim
panel retaining screw.
31. Remove the lower seat trim panel screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8941
32. Remove the lower seat trim panel.
1 Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel
from the seat bottom frame.
2 Remove the lower seat trim panel.
33. Remove the push pin holder from the seat bottom frame for the lumbar support cable.
NOTE: Install a new pin-type retainer if damaged.
34. Separate the lumbar support cable assembly.
1 Separate the lumbar support case assembly by sliding apart.
2 Remove the cable end ball from the cable end retainer and separate.
35. Separate the side air bag electrical connector and wire harness from the seat bottom frame.
1 Release the finger clip and slide the side air bag electrical connector off the bracket.
2 Separate the side air bag wire harness pin-type retainer from the seat bottom frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8942
NOTE: Install new pin-type retainers if damaged.
36. Remove the two bolts.
37. Laying the seat on its other side, remove the retaining bolt for the seat pivot.
CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
38. Remove the seat back from the seat bottom.
1 Note the routing, and pull the lumbar support cable through the seat bottom.
2 Note the routing, and pull the side air bag module wire harness through the seat bottom.
3 Remove the seat back from the seat bottom.
WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH A
SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS
PERMISSIBLE).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8943
39. Separate the seat back trim cover lower J-clip.
40. Remove and discard the hog rings from the two swing rods (one shown).
41. Slide the swing rods out of the seat back trim cover.
42. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The
hook and loop strip can be torn from the seat cushion foam.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8944
43. Remove and discard the tie-strap holding the deployment chute tail and side air bag wire
harness in place.
44. Unzip the side air bag deployment chute.
45. Roll the seat back cover and side air bag deployment chute to completely expose the side air
bag module, mounting bracket and side air bag shield.
46. Remove and discard the duct tape retaining the side air bag shield.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8945
47. Separate the side air bag wiring harness pin-type retainers from the seat back frame.
48. Remove the side air bag stud covers.
49. Remove the side air bag module nuts.
NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag
module is to be reused, then reuse the side air bag module retaining nuts.
50. Position the side air bag module and shield out through the seat back cushion opening.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8946
51. Remove the side air bag module.
1 Slide the side air bag module electrical connector locking clip to disengage it.
2 Release the connector tabs by pushing in on them, then disconnect the side air bag module
electrical connector.
3 Remove the side air bag module.
52. Remove the shield from the side air bag module.
Installation
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if
equipped)system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8947
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ When replacing the side air bag after deployment.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Install the shield onto the side air bag module.
2. Connect the side air bag module electrical connector.
1 Install the connector to the side air bag module.
2 Slide the side air bag module electrical connector locking clip to secure the connector to the side
air bag module.
3. Make sure the electrical connector is securely fastened to the side air bag module.
4. Position the side air bag module and shield into the seat backrest cushion.
WARNING: ^
INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT
BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING
THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG
DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN
THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE
FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE
EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO
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Repair > Driver Side > Page 8948
SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN
EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR
BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF
AN AIR BAG DEPLOYMENT.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT
IN PERSONAL INJURY.
5. Position the side air bag module studs, with the shield still in place, through the seat backrest
mounting bracket holes.
^ Do not pinch the side air bag module wiring harness between the side air bag module and the
mounting bracket.
CAUTION: Make sure the side air bag wiring harness is not pinched between the side air bag
module and the mounting bracket.
6. Route the side air bag module wire harness. Install the side air bag nuts and tighten in the
sequence shown.
1 Route the side air bag module wire harness to the back side of the side air bag mounting bracket
making sure it is not pinched between the side air bag module and the mounting bracket.
2 Install the side air bag nut.
3 Install the side air bag nut.
4 Install the side air bag nut.
CAUTION: ^
The retaining nuts of the side air bag module must be tightened in the sequence described.
^ Make sure the side air bag wiring harness is not pinched between the side air bag module and
the mounting bracket.
7. Install the side air bag stud covers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8949
8. Position the side air bag shield to the seat backrest frame.
1 Apply new duct tape to the side air bag shield.
2 Position the side air bag module wire harness so that it will fit loosely between the side air bag
shield and the mounting bracket.
3 Position the side air bag shield to the seat backrest frame keeping it in place with the tape. ^
Check that the side air bag module wire harness fits loosely between the side air bag shield and
the mounting bracket and is not pinched.
9. Route the side air bag wire harness and install the pin-type retainers to the seat back frame.
10. Unroll the seat back trim cover, to position the deployment chute around the side air bag
module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8950
11. Position the air bag deployment chute.
1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side
air bag module, pulling it around the outboard side of the seat back frame.
2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side
air bag module from the inboard side of the seat back.
WARNING: ^
CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.
12. Zip the air bag deployment chute completely closed, then position the zipper tail at the top of
the deployment chute, into the seat back opening.
^ The side air bag deployment chute must encircle the side air bag module, going completely
around the side air bag module and the side of the seat back frame.
^ Align the side air bag deployment chute to the side air bag module, making sure it covers the
length of the side air bag module.
NOTE: Be sure the side air bag deployment chute is correctly positioned, before proceeding.
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13. Position the deployment chute tail and side air bag wire harness and tie-strap them in place.
14. Unroll the seat back trim cover to the bottom row of hog rings.
15. Install the swing rods back into the seat back trim cover sleeves.
16. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog
rings, position the top of the swing rods under the
listing wire in the seat back pad.
NOTE: The seat back trim cover has been inverted for clarity.
17. Install new hog rings onto the swing rods (one shown). 18. Pull the seat back rest trim cover
completely down and connect the hook and loop fastener to the seat back cushion.
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Repair > Driver Side > Page 8952
19. Reattach the seat back trim cover lower J-clips.
20. Position the seat back to the seat bottom and route the wires and cables.
1 Position the seat back to the seat bottom.
2 Pull the side air bag module wire harness through the seat bottom.
3 Pull the lumbar support cable through the seat bottom.
21. Align the seat back to the seat bottom. Install the bolt and tighten to specification.
CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to.
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
22. Install the two bolts and tighten to specification.
CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8953
23. Route the side air bag module wire harness.
1 Slide the side air bag wire harness onto the finger clip.
2 Install the side air bag wire harness pin-type retainer into the seat bottom frame.
24. Connect the lumbar support cable assembly.
1 Install the cable end ball to the cable end retainer.
2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot.
25. Install the push pin holder to the seat bottom frame and insert the lumbar support cable.
26. Install the seat bottom lower side shield into the seat bottom frame.
1 Align the seat bottom lower side shield retaining clips to the seat bottom.
2 Push in on the lower side shield, seating the clips (one shown) into the seat bottom frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8954
27. Install the lower side shield screw.
28. Install the lower side shield retaining screw and the lumbar support handle.
29. Connect the power seat switch electrical connector.
30. Position the seat track to the seat bottom frame. Install the four bolts and lighten to
specification.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8955
31. Connect the seat motor electrical connector. 32. Position the driver seat into the vehicle. Install
and hand-tighten the four seat track to floor bolts.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
33. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
34. Connect the driver seat side air bag and power seat electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
3 Tie-strap the wire harness.
35. Connect the battery ground cable. 36. Position the driver seat rearward. 37. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system. See: Air Bag(s) Arming
and Disarming
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8956
38. Tighten in sequence the driver seat front track to floor bolts.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
39. Move and tilt the driver seat to its highest and most forward position.
40. Tighten in sequence the driver seat rear track to floor bolts.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
41. Install the driver seat rear track bolt covers.
42. Connect the safety belt warning indicator electrical connector.
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Repair > Driver Side > Page 8957
43. Using the special tool, install the safety belt buckle support assembly bolt.
44. Install the safety belt buckle support assembly bolt cover. 45. Position the driver seat rearward.
46. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
47. Position the passenger seat forward.
48. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8958
49. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 50.
Position the passenger seat rearward.
51. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
52. Install the passenger air bag module.
53. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
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Repair > Driver Side > Page 8959
54. Connect the clockspring electrical connector at the base of the steering column.
55. Position the lower steering column opening finish panel reinforcement and install the bolts.
56. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top seating
the retaining clips.
2 Install the screws.
57. Position the hood release handle and install the screws. 58. Connect the battery ground cable.
59. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and
Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF
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Repair > Driver Side > Page 8960
VEHICLE SAFETY STANDARDS.
60. Check the restraint system for correct operation.
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Repair > Driver Side > Page 8961
Side Air Bag: Service and Repair Passenger Side
Removal
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
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connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat Systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ When replacing the side air bag after deployment.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the passenger seat rearward.
2. Remove the passenger seat front track to floor bolts. 3. Move and tilt the front seats to their
highest and most forward position. 4. Disconnect the battery ground cable and wait at least one
minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
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6. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support assembly bolt cover plug.
8. Using the special tool, remove the safety belt buckle support assembly bolt.
9. Remove the passenger seat rear bolt trim covers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
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10. Remove the passenger seat rear bolts. 11. Remove the passenger seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly.Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 14. Connect the battery ground cable. 15. Position the driver seat rearward. 16.
Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
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17. Remove the retaining screws and position the hood release handle out of the way.
18. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
19. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
20. Disconnect the clockspring electrical connector at the base of the steering column.
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Repair > Driver Side > Page 8966
21. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 22. Remove the passenger air bag module.
23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 24. Connect the battery ground cable. 25. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and
Disarming 26. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE: Driver seat is shown, passenger seat is similar.
27. Remove the four bolts and the seat track from the seat bottom. 28. Turn the manual lumbar
handle clockwise until it stops, releasing all tension on the manual lumbar support cable.
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29. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim
panel retaining screw.
30. Remove the side shield screw.
31. Remove the lower seat trim panel.
1 Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel
from the seat bottom frame.
2 Remove the lower seat trim panel.
32. Remove the push pin holder from the seat bottom frame for the lumbar support cable.
NOTE: Install a new pin-type retainer if damaged.
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33. Separate the lumbar support cable assembly.
1 Separate the lumbar support case assembly by sliding apart.
2 Remove the cable end ball from the cable end retainer and separate.
34. Separate the side air bag electrical connector and wire harness from the seat bottom frame.
1 Release the finger clip and slide the side air bag electrical connector off the bracket.
2 Separate the side air bag wire harness pin-type retainer form the seat bottom frame.
NOTE: Install new pin-type retainers if damaged.
35. Remove the two bolts.
36. Laying the seat on its other side, remove the retaining bolt for the seat pivot.
CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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37. Remove the seat back from the seat bottom.
1 While noting the routing, pull the lumbar support cable through the seat bottom.
2 While noting the routing, pull the side air bag module wire harness through the seat bottom.
3 Remove the seat back front the seat bottom.
WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE
AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEARING IS
PERMISSIBLE).
38. Separate the seat back trim cover lower J-clip.
39. Remove and discard the hog rings from the two swing rods (one shown).
40. Slide the swing rods out of the seat back trim cover.
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Repair > Driver Side > Page 8970
41. Roll the seat back trim cover, in an inside-out fashion, to the side air bag deployment chute.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The
hook and loop strip can be torn from the seat cushion foam.
42. Remove and discard the tie-strap holding the deployment chute tail and side air bag wire
harness in place.
43. Unzip the side air bag deployment chute.
44. Roll the seat back cover and side air bag deployment chute to completely expose the side air
bag module, mounting bracket and side air bag shield.
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45. Remove and discard the duct tape retaining the side air bag shield.
46. Separate the side air bag wiring harness pin-type retainers from the seat back frame.
47. Remove the side air bag stud covers.
48. Remove the side air bag module nuts.
NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag
module is to be reused, then reuse the side air bag module retaining nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8972
49. Position the side air bag module and shield out through the seat back cushion opening.
50. Remove the side air bag module.
1 Slide the side air bag module electrical connector locking clip to disengage it.
2 Release the connector tabs by pushing in on them, then disconnect the side air bag module
electrical connector.
3 Remove the side air bag module.
51. Remove the shield from the side air bag module.
Installation
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
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AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION,
INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION.
REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR
BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ When installing a new side air bag after deployment.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ Driver seat is shown, passenger seat is similar.
1. Install the shield onto the side air bag module.
2. Connect the side air bag module electrical connector.
1 Install the connector to the side air bag module.
2 Slide the side air bag module electrical connector locking clip to secure the connector to the side
air bag module.
3. Make sure the electrical connector is securely fastened to the side air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
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4. Position the side air bag module and shield into the seat backrest cushion.
WARNING: ^
INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT
BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING
THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG
DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN
THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE
FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE
EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN
EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR
BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF
AN AIR BAG DEPLOYMENT.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT
IN PERSONAL INJURY.
5. Position the side air bag module studs, with the shield still in place, through the seat backrest
mounting bracket holes.
^ Do not pinch the side air bag module wiring harness between the side air bag module and the
mounting bracket.
CAUTION: Make sure the side air bag wiring harness is not pinched between the side air bag
module and the mounting bracket.
6. Route the side air bag module wire harness. Install the side air bag nuts and tighten in the
sequence shown.
1 Route the side air bag module wire harness to the back side of the side air bag mounting bracket,
making sure it is not pinched between the side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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air bag module and the mounting bracket.
2 Install the side air bag nut.
3 Install the side air bag nut.
4 Install the side air bag nut.
CAUTION: ^
The retaining nuts of the side air bag module must be tightened in the sequence described.
^ Make sure the side air bag wiring harness is not pinched between the side air bag module and
the mounting bracket.
7. Install the side air bag stud covers.
8. Position the side air bag shield to the seat backrest frame.
1 Apply new tape to the side air bag shield.
2 Position the side air bag module wire harness so that it will fit loosely between the side air bag
shield and the mounting bracket.
3 Position the side air bag shield to the seat backrest frame keeping it in place with the tape. ^
Check that the side air bag module wire harness fits loosely between the side air bag shield and
the mounting bracket and is not pinched.
9. Route the side air bag wire harness and install the pin-type retainers to the seat back frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8976
10. Unroll the seat back trim cover, to position the deployment chute around the side air bag
module.
11. Position the air bag deployment chute.
1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side
air bag module, pulling it around the outboard side of the seat back frame.
2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side
air bag module from the inboard side of the seat back.
WARNING: ^
CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.
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Repair > Driver Side > Page 8977
12. Zip the air bag deployment chute completely closed, then position the zipper tail at the top of
the deployment chute, into the seat back opening.
^ The side air bag deployment chute must encircle the side air bag module, going completely
around the side air bag module and the side of the seat back frame.
^ Align the side air bag deployment chute to the side air bag module, making sure it covers the
length of the side air bag module.
NOTE: Be sure the side air bag deployment chute is correctly positioned, before proceeding.
13. Position the deployment chute tail and side air bag wire harness and tie-strap them in place.
14. Unroll the seat back trim cover to the bottom row of hog rings.
15. Install the swing rods back into the seat back trim cover sleeves.
16. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog
rings, position the top of the swing rods under the
listing wire in the seat back pad.
NOTE: The seat hack trim cover has been inverted for clarity.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
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17. Install new hog rings onto the swing rods (one shown). 18. Pull the seat back rest trim cover
completely down and connect the hook and loop fastener to the seat back cushion.
19. Reattach the seat back trim cover lower J-clips.
20. Position the seat back to the seat bottom and route the wires and cables.
1 Position the seat back to the seat bottom.
2 Pull the side air bag module wire harness through the seat bottom.
3 Pull the lumbar support cable through the seat bottom.
21. Align the seat back to the seat bottom. Install the bolt and tighten to specification.
CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8979
22. Install the two bolts and tighten to specification.
CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
23. Route the side air bag module wire harness.
1 Slide the side air bag wire harness onto the finger clip.
2 Install the side air bag wire harness pin-type retainer into the seat bottom frame.
24. Connect the lumbar support cable assembly.
1 Install the cable end ball to the cable end retainer.
2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot.
25. Install the push pin holder to the seat bottom frame and insert the lumbar support cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Repair > Driver Side > Page 8980
26. Install the seat bottom lower side shield into the seat bottom frame.
1 Align the seat bottom lower side shield retaining clips to the seat bottom.
2 Push in on the lower side shield, seating the clips (one shown) into the seat bottom frame.
27. Install the lower side shield screw.
28. Install the lower side shield retaining screw and the lumbar support handle.
29. Position the seat track to the seat bottom frame. Install the tour bolts and tighten to
specification. 30. Position the passenger seat into the vehicle. Install and hand tighten the four seat
track-to-floor bolts
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8981
31. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
32. Connect the passenger seat side air bag electrical connector and tic-strap the wire harness. 33.
Connect the battery ground cable. 34. Position the front seats rearward. 35. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
36. Tighten in sequence the passenger seat front track-to-floor bolts.
1 Tighten to specification the front inboard bolt.
2 Tighten to specification the front outboard bolt.
37. Move and tilt the front seats to their highest and most forward position. 38. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL; CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE, BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
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Repair > Driver Side > Page 8982
39. Tighten in sequence the passenger seat rear track-to-floor bolts.
1 Tighten to specification the rear inboard bolt.
2 Tighten to specification the rear outboard bolt.
40. Install the passenger seat rear track bolt covers.
41. Using the special tool, install the safety belt buckle support assembly bolt.
42. Install the safety belt buckle support assembly bolt cover.
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Repair > Driver Side > Page 8983
43. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
44. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 45.
Connect the battery ground cable. 46. Position the front seats rearward. 47. Disconnect the battery
ground cable and wait at least one minute.
48. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8984
49. Connect the clockspring electrical connector at the base of the steering column.
50. Position the lower steering column opening finish panel reinforcement and install the bolts.
51. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the instrument panel. Push in the top
of the lower steering column opening finish panel to seat the retaining clips.
2 Install the screws.
52. Position the hood release handle and install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side > Page 8985
53. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
54. Install the passenger air bag module. 55. Connect the battery ground cable. 56. With all the
diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
57. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Page 8986
Special Tool(s)
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8992
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8993
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8994
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8995
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8996
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8997
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8998
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Component Information > Technical Service Bulletins > Page 8999
Air Bag Control Module: Specifications
Restraints Control Module Bolts 12 Nm
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Component Information > Technical Service Bulletins > Page 9000
Air Bag Control Module: Locations
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 9001
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 9002
Air Bag Control Module: Diagrams
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Component Information > Technical Service Bulletins > Page 9003
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Technician Safety Information
Air Bag Control Module: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Technician Safety Information > Page 9006
Air Bag Control Module: Vehicle Damage Warnings
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Page 9007
Air Bag Control Module: Description and Operation
The Restraints Control Module (RCM) carries out the following functions:
^ signals the inflators to deploy the air bags in the event of a deployable crash.
^ monitors the air bag supplemental restraint system (SRS) for faults.
^ illuminates the air bag indicator if a fault is detected.
^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic
Trouble Codes (DTCs).
^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safing sensor is internal to the RCM and is not serviced separately.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the RUN position, the RCM will flash the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the
LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also
communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag
indicator does not function, and the system detects a fault condition, the RCM will signal the GEM
to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is
heard, the SRS and the air bag indicator require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors determine that a deployment is required. The backup power supply will deplete its
stored energy approximately one minute after the battery ground cable is disconnected.
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Component Information > Service Precautions > Page 9008
Air Bag Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Air Bag Systems; Testing and Inspection.
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Component Information > Service and Repair > Restraints Control Module
Air Bag Control Module: Service and Repair Restraints Control Module
With Side Air Bags
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9011
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9012
4. Remove the retaining bolts and remove the lower steering column opening finish panel
reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9013
SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR
STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS
DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD
LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9014
15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18.
Reconnect the battery ground cable. 19. With the restraint system diagnostic tools installed at all
deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s)
Arming and Disarming
20. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
21. Remove the full floor console.
Vehicles with a restraint control module cover
22. Remove the mat, the screws and the Restraint Control Module (RCM) cover.
23. Remove the right-hand side RCM retaining bolts
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9015
24. Remove the RCM.
1 Slide and disengage the two RCM electrical connector locking clips.
2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect.
3 Remove the retaining bolt.
4 Remove the RCM.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Position the RCM to the center tunnel area and install the three bolts hand-tight.
WARNING: ^
THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and
safety belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9016
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Tighten the right-hand side RCM bolts to specification.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Connect the RCM.
1 Tighten the bolt to specification.
2 Connect the RCM electrical connectors.
3 Slide and engage the RCM electrical connector locking clips.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all
deployable devices, prove out the air bag system.
6. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9017
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
7. Install the full floor console.
Vehicles with a restraint control module cover
8. Position the RCM cover. Install the screws and the mat.
9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
10. Connect the clockspring electrical connector at the base of the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9018
11. Position the lower steering column opening finish panel reinforcement and install the bolts.
12. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top seating
the retaining clips.
2 Install the screws.
13. Position the hood release handle and install the screws.
14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9019
15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. Move and tilt
the front seats to their highest and most forward position. 18. Disconnect the battery ground cable
and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
19. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
21. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9020
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
22. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 23.
Connect the battery ground cable. 24. Position the front seats rearward. 25. Connect the battery
ground cable. 26. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag
Systems/Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Without Side Air Bags
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9021
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9022
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
4. Remove the retaining bolts and remove the lower steering column opening finish panel
reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9023
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Reconnect the battery ground cable.
10. With the restraint system diagnostic tools installed at all deployable devices, prove out the air
bag system. See: Air Bag Systems/Air Bag(s)
Arming and Disarming
11. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
12. Remove the full floor console.
Vehicles with a restraint control module cover
13. Remove the mat, the screws and the Restraint Control Module (RCM) cover.
14. Remove the right-hand side RCM retaining bolts
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9024
15. Remove the RCM.
1 Slide and disengage the two RCM electrical connector locking clips.
2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect.
3 Remove the retaining bolt.
4 Remove the RCM.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE
EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE
CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Position the RCM to the center tunnel area and install the three bolts hand-tight.
WARNING: ^
THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and
safety belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9025
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Tighten the right-hand side RCM bolts to specification.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Connect the RCM.
1 Tighten the bolt to specification.
2 Connect the RCM electrical connectors.
3 Slide and engage the RCM electrical connector locking clips.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
4. Connect the battery ground cable.
5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air
bag system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9026
6. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Vehicles with full floor console
7. Install the full floor console.
Vehicles with a restraint control module cover
8. Position the RCM cover. Install the screws and the mat.
9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9027
10. Connect the clockspring electrical connector at the base of the steering column.
11. Position the lower steering column opening finish panel reinforcement and install the bolts.
12. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top seating
the retaining clips.
2 Install the screws.
13. Position the hood release handle and install the screws.
14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9028
VEHICLE SAFETY STANDARDS.
15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. With all the
diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming
and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9029
Air Bag Control Module: Service and Repair Weld Nut Repair
"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control
Module (RCM) and Side Crash Sensor before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut
Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts
must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and
Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification. Refer to Torque Specifications.
Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM)
and Side Crash Sensor before proceeding with the repair.
^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld
Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-S190).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Restraints Control Module > Page 9030
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification. Refer to Torque Specifications.
Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE
LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Refer to Torque Specifications.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Page 9031
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
9036
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
9037
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
9038
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
9039
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
9040
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
9041
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
9042
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay >
Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation
Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation
Article No. 01-2-5
2/05/01
^ TRIM - SEAT BELT WARNING SYSTEM - "BELT
^ MINDER" FUNCTION - OPERATION AND SERVICE
^ TIPS
^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND
^ SERVICE TIPS
FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION,
F-150, RANGER, WINDSTAR 2001 EXPLORER
LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR
MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER
ISSUE
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning
function. This feature provides additional reminders to the driver that the driver's safety belt is
unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the
instrument cluster.
ACTION
Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by
performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt
Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following
Service Procedure.
SERVICE PROCEDURE
To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure.
1. Establish a session for the vehicle.
2. Select the "Toolbox" icon.
3. Select "Module Programming" and press the "Tick" mark.
4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark.
5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark.
6. WDS will display "Configuration Complete", then press the "Tick" mark.
NOTE:
IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT
LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH
HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT
WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS
EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE
SAFETY BELT IS BUCKLED.
NOTE:
WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND
CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT
WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND
FOR 4-8 SECONDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay >
Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9047
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 104000, 204000, 206000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Seats Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Disconnect the battery ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical
connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air
bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor
connector.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side floor connector. 11. Reconnect the battery ground cable.
Seats Not Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery
ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9053
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate
controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint
system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector
to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector
beneath the front seat.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
passenger side air bag electrical connector beneath
the front seat.
11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat.
12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side air bag electrical connector beneath the
front seat.
13. Reconnect the battery ground cable.
Deactivation Procedure
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will This will
reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9054
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood connected.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9055
8. Remove the driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
11. Open the glove compartment door past its stops to access the mounting screws.
12. Remove the two screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9056
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door. Reaching one hand into the glove
compartment opening push out on the passenger air bag module and separate it from the
instrument panel. Note the wire harness routing for installation.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
Vehicles without seat side air bags
16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag
bridge resistor from the side air bag to floor connector.
If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints
control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor
connector, a low resistance fault will be generated by the RCM.
Vehicles with seat side air bags and power driver seat
17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the battery ground
cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Vehicles with seat side air bags
18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side
air bags and power driver seat
19. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery
ground cable (14301) and wait at least one minute. For additional information, See: Starting and
Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9057
Vehicles with seat side air bags
20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
All vehicles
24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close
the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery
Reactivation Procedure
Reactivation
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9058
1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the
instrument panel, open the kick panel cover and remove the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the wiring Diagram Manual.
3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
Vehicles with seat side air bags
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
Vehicles with seat side air bags and power driver seat
8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9059
Vehicles with seat side air bags
9. Position the front seats rearward.
Vehicles with seat side air bags and power driver seat
10. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air
bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply
energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery
All vehicles
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical
connector.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Position the passenger air bag module into the instrument panel. Route the wire harness as noted
in removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9060
14. Install the two screws.
15. Close the glove compartment door.
16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
17. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to
the steering wheel.
18. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9061
19. Install the two steering wheel back cover plugs.
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear
blower, 15A with rear blower) to the CJB and close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to
OFF. Wait 10 seconds, then turn the key back to
ON and visually monitor the air bag indicator with the air bag modules installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an air bag
supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light.
-remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after
the ignition switch has been turned from the OFF to the ON position. This is the time required for
the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is
inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this
occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
25. Clear all continuous DTCs from the restraints control module using a scan tool.
Procedures For Repair Operations
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9062
accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9063
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9064
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9065
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9066
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Seats Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic
tool from the driver seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger
seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic
tool from the clockspring connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9067
8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable.
10. Prove out the system.
Seats Not Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring
connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove
the restraint system diagnostic tool from the floor connector beneath the front passenger seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the
passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from
the floor connector beneath the driver seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver
seat.
10. Reconnect the battery ground cable. 11. Prove out the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9068
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9069
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint
System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Description and Operation
Child Seat Tether Attachment: Description and Operation
Some manufacturers make child safety seats that include a tether strap that goes over the back of
the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as
an accessory. Contact the manufacturer of the child safety seat for information about ordering a
tether strap.
The child safety seat tether strap anchors (cargo tie-downs) are located behind the second (2nd)
row seat on the load floor. If the tether strap anchors were in use during a collision install new
anchors and repair the load floor to its original condition and structural integrity.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Restraints - Seat Belt Stop Button Service
Seat Belt: Technical Service Bulletins Restraints - Seat Belt Stop Button Service
TSB 05-3-10
02/21/05
SAFETY BELT WEB STOP BUTTON SERVICE
FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty
2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005
Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005
Escape Hybrid
LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator
MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey
ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding
down when not in use), a service kit is now available.
ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow
the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of
the appropriate model year Workshop Manual for additional information if needed.
NOTE
ONE KIT WILL REPAIR ONE SEAT BELT BUTTON.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
70611B09 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications >
Two Door
Seat Belt: Specifications
Two Door Models
Rear Seat Center Occupant Safety Belt Retractor And Passenger Side Safety Belt Buckle
Assembly Bolt 40 Nm
Safety Belt Retractor Bolts 40 Nm
Safety Belt Anchor Bolts 40 Nm
Safety Belt Slide Bar-to-Floor Bolt 40 Nm
Safety Belt Slide Bar-to-Seat Track Bolt 9 Nm
Safety Belt Slide Bar-to-Seat Track Nut 9 Nm
Safety Belt Guide Bolt 40 Nm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications >
Two Door > Page 9080
Seat Belt: Specifications
Four Door Models
Front Safety Belt Retractor Upper Sheet Metal Bolt 7 Nm
Safety Belt Anchor Bolts 40 Nm
Safety Belt Slide Bar-to-Floor Bolt 40 Nm
Safety Belt Slide Bar-to-Seat Track Bolt 9 Nm
Safety Belt Slide Bar-to-Seat Track Nut 9 Nm
Safety Belt Guide Bolt 40 Nm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications >
Page 9081
Seat Belt: Service Precautions
WARNING:
^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT
BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF
SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING
HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES
SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES
SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A
COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR
IMPROPER OPERATION IS NOTED.
^ AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD
SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING
RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERITY
THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL
FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT
SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE
SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY
OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED
ACCORDING TO THE PROCEDURES. FAILURE TO REPLACE THE BELT AND RETRACTOR
ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor
Seat Belt: Service and Repair Front Safety Belt and Retractor
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
All Vehicles
1. Pull to release the retaining clips and remove the windshield side garnish molding.
2. Pull up to release the retaining clips and remove the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9084
3. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
4. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
5. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 6.
Position the carpet aside at the front safety belt anchor.
7. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9085
8. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
3 Remove the quarter trim panel front screw.
9. Fold the rear seat into the load floor position.
10. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
11. Remove the retractable cargo cover.
All vehicles
12. Remove the rear safety belt guide.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9086
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
3 Remove the rear safety belt guide.
13. Position the carpet aside at the rear safety belt anchor.
14. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
15. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
16. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9087
17. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
Vehicles with a rear power lock switch
18. Through the jack access panel, release the rear power lock switch assembly retaining tab and
pull the switch through.
19. Disconnect and remove the rear power lock switch assembly.
All Vehicles
20. Remove the pin-type retainers from the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9088
21. Slide the quarter trim panel forward and disengage it from the door jamb.
22. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
23. Remove the safety belt web guide.
1 Remove the bolt.
2 Remove the safety belt web guide from the B-pillar.
24. Remove the front safety belt retractor.
1 Using the special tool, remove the bolt.
2 Remove the front safety belt retractor.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9089
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
All Vehicles
1. Install the front safety belt retractor.
1 Position the front safety belt retractor to the B-pillar.
2 Using the special tool, install the bolt.
NOTE: Make sure to tighten nuts and bolts to specification.
2. Install the safety belt web guide.
1 Position the safety belt web guide to the B-pillar.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
3. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbings through the openings in the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9090
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
4. Slide back and engage the edge of the quarter trim panel into the doorjamb.
5. Install the quarter trim panel rear screws.
6. Through the front door opening, install the quarter trim front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
7. Install the pin-type retainers into the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9091
8. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
9. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Vehicles with a rear power lock switch
10. Connect and install the rear power lock switch assembly into the rear quarter trim panel.
All Vehicles
11. Position the washer on the rear safety belt guide bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9092
12. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
13. Fold the rear seat into the load floor position.
14. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
15. Reposition the carpet back over the floor.
16. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo cover
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9093
17. Install the retractable cargo cover.
All Vehicles
18. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
19. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9094
20. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
21. Reposition the carpet at the front safety belt anchor.
22. Align the retaining clips and install the front door scuff plate.
23. Align the retaining clips and install the windshield side garnish molding. 24. Reposition the rear
seat back up. 25. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9095
Seat Belt: Service and Repair Rear Safety Belt and Retractor
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
All Vehicles
1. Pull to release the retaining clips and remove the windshield side garnish molding.
2. Pull up to release the retaining clips and remove the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9096
3. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
4. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
5. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 6.
Position the carpet aside at the front safety belt anchor.
7. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9097
8. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
3 Remove the quarter trim panel front screw.
9. Fold the rear seat into the load floor position.
10. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
11. Remove the retractable cargo cover.
All Vehicles
12. Remove the rear safety belt guide.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9098
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
3 Remove the rear safety belt guide.
13. Position the carpet aside at the rear safety belt anchor.
14. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
15. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
16. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9099
17. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
Vehicles with rear power lock switch
18. Through the jack access panel, release the rear power lock switch assembly retaining tab and
pull the switch through.
19. Disconnect and remove the rear power lock switch assembly.
All Vehicles
20. Remove the pin-type retainers from the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9100
21. Slide the quarter trim panel forward and disengage it from the doorjamb.
22. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
23. Remove the rear safety belt retractor.
1 Using the special tool, remove the bolt.
2 Remove the rear safety belt retractor.
INSTALLATION
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
All Vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9101
1. Install the rear safety belt retractor.
1 Position the rear safety belt retractor to the B-pillar.
2 Using the special tool, install the bolt.
NOTE: Make sure to tighten nuts and bolts to specification.
2. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbings through the openings in the quarter trim panel.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
3. Slide back and engage the edge of the quarter trim panel into the door jamb.
4. Install the quarter trim panel rear screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9102
5. Through the front door opening, install the quarter trim panel front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim panel front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
6. Install the pin-type retainers into the quarter trim panel.
7. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
8. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9103
Vehicles with rear power lock switch
9. Connect and install the rear power lock switch assembly into the rear quarter trim panel.
All Vehicles
10. Position the washer on the rear safety belt guide bolt.
11. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
12. Fold the rear seat into the load floor position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9104
13. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
14. Reposition the carpet back over the floor.
15. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo covers
16. Install the retractable cargo cover.
All Vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9105
17. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
18. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
19. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
20. Reposition the carpet at the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Safety Belt and Retractor > Page 9106
21. Align the retaining clips and install the front door scuff plate.
22. Align the retaining clips and install the windshield side garnish molding. 23. Reposition the rear
seat back up. 24. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Page 9107
Seat Belt Bolt Bit (Used For T-50 Head Bolt)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Specifications
Seat Belt Buckle: Specifications
Front Safety Belt Buckle-To-Slide Bar Bolt 40 Nm
Rear Seat Center Occupant Safety Belt Retractor And Passenger Side Safety Belt Buckle
Assembly Bolt 40 Nm
Rear Seat Safety Belt Buckle Assembly Front Nuts 40 Nm
Rear Seat Safety Belt Buckle Assembly Rear Nuts 48 Nm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
Precautions > Technician Safety Information
Seat Belt Buckle: Technician Safety Information
WARNING:
^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT
BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF
SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING
HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES
SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES
SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A
COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR
IMPROPER OPERATION IS NOTED.
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE THE RESTRAINT SYSTEM DIAGNOSTIC TOOL FROM THE PASSENGER
SEAT SIDE AIR BAG FLOOR ELECTRICAL CONNECTOR.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
Precautions > Technician Safety Information > Page 9113
Seat Belt Buckle: Vehicle Damage Warnings
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle can result in damaged components.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag
Seat Belt Buckle: Service and Repair Front Seats Without Side Air Bag
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
NOTE: Driver side is shown, passenger side is similar.
1. Remove the front driver or passenger seat from the vehicle.
2. Remove the safety belt buckle support assembly.
1 Remove the nut.
2 Remove the bolt.
3 Remove the safety belt buckle support assembly.
3. Remove the safety belt buckle.
1 Clamp the safety belt buckle support assembly in a suitable vise.
2 Using the special tool, remove the safety belt buckle bolt.
3 Remove the safety belt buckle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9116
NOTE: Clamp the safety belt buckle support assembly collar in a vise along the break line only.
INSTALLATION
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Install the safety belt buckle onto the safety belt buckle support assembly.
1 Position the safety belt buckle onto the safety belt buckle support assembly.
2 Using the special tool, install the safety belt buckle bolt.
3 Remove the safety belt buckle support assembly from the vise.
2. Install the safety belt buckle support assembly onto the seat.
1 Position the safety belt buckle support assembly to the seat.
2 Install the nut and bolt.
3. Install the front driver or passenger seat into the vehicle. 4. Check the restraint system for
correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9117
Seat Belt Buckle: Service and Repair Driver Seat With Side Air Bag
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT
BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF
SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING
HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES
SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES
SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A
COLLISION SHOULD ALSO BE INSPECTED AND INSTALL NEW IF EITHER DAMAGE OR
INCORRECT OPERATION IS NOTED.
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9118
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9119
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support assembly bolt cover plug.
8. Using the special tool, remove the safety belt buckle support assembly bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9120
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle can result in damaged components.
13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9121
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9122
21. Disconnect the air bag sliding contact electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the air bag sliding
contact electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s)
Arming and Disarming 25. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
26. Remove the safety belt buckle support assembly.
1 Remove the nut.
2 Remove the bolt.
3 Remove the safety belt buckle support assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9123
27. Remove the safety belt buckle.
1 Clamp the safety belt buckle support assembly in a suitable vise.
2 Using the special tool, remove the safety belt buckle bolt.
3 Remove the safety belt buckle.
NOTE: Clamp the safety belt buckle support assembly collar in a vise along the break line only.
INSTALLATION
WARNING:
^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT
BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF
SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING
HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES
SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES
SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A
COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR
IMPROPER OPERATION IS NOTED.
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced, the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system, the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9124
1. Install the safety belt buckle onto the safety belt buckle support assembly.
1 Position the safety belt buckle onto the slide bar.
2 Using the special tool, install the safety belt buckle bolt.
3 Remove the safety belt buckle support assembly from the vise.
2. Install the safety belt buckle support assembly onto the seat.
1 Position the safety belt buckle support assembly to the seat.
2 Install the nut and bolt.
3. Position the driver seat into the vehicle. Install and hand tighten the four seat track-to-floor bolts.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle can result in damaged components.
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9125
5. Connect the driver seat side air bag and power seat electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
3 Tie-strap the wire harness.
6. Connect the battery ground cable. 7. Position the driver seat rearward. 8. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
9. Tighten in sequence the driver seat front track-to-floor bolts.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
10. Move and tilt the driver seat to its highest and most forward position.
11. Tighten in sequence the driver seat rear track-to-floor bolts.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9126
12. Install the driver seat rear track bolt covers.
13. Connect the safety belt warning indicator electrical connector.
14. Using the special tool, install the safety belt buckle support assembly bolt.
15. Install the safety belt buckle support assembly bolt cover. 16. Position the driver seat rearward.
17. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9127
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
18. Position the passenger seat forward.
19. Remove from vehicle prior to road use. Failure to remove can result in injury and possible
violation of vehicle safety standards.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE THE RESTRAINT SYSTEM DIAGNOSTIC TOOL FROM THE
PASSENGER SEAT SIDE AIR BAG FLOOR ELECTRICAL CONNECTOR.
20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 21.
Position the passenger seat rearward.
22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
23. Install the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9128
24. Remove the restraint system diagnostic tool from the vehicle harness side of the air bag sliding
contact electrical connector at the base of the
steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS LOT RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
25. Connect the air bag sliding contact electrical connector at the base of the steering column.
26. Position the lower steering column opening finish panel reinforcement and install the bolts.
27. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9129
28. Position the hood release handle and install the screws. 29. Connect the battery ground cable.
30. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and
Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
31. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9130
Seat Belt Buckle: Service and Repair Passenger Seat With Side Air Bag
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT
BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF
SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING
HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES
SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES
SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A
COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR
IMPROPER OPERATION IS NOTED.
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT
IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9131
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced, the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system, the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
1. Position the passenger seat rearward.
2. Remove the passenger seat front track to floor bolts. 3. Move and tilt the front seats to their
highest and most forward position. 4. Disconnect the battery ground cable and wait at least one
minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9132
6. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support assembly bolt cover plug.
8. Using the special tool, remove the safety belt buckle support assembly bolt.
9. Remove the passenger seat rear bolt trim covers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9133
10. Remove the passenger seat rear bolts. 11. Remove the passenger seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle can result in damaged components.
12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 14. Connect the battery ground cable. 15. Position the driver seat rearward. 16.
Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS.., SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9134
17. Remove the retaining screws and position the hood release handle out of the way.
18. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
19. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
20. Disconnect the air bag sliding contact electrical connector at the base of the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9135
21. Attach the restraint system diagnostic tool to the vehicle harness side of the air bag sliding
contact electrical connector. 22. Remove the passenger air bag module.
23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 24. Connect the battery ground cable. 25. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and
Disarming 26. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
27. Remove the safety belt buckle support assembly.
1 Remove the nut.
2 Remove the bolt.
3 Remove the safety belt buckle support assembly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9136
28. Remove the safety belt buckle.
1 Clamp the safety belt buckle support assembly in a suitable vise.
2 Using the special tool, remove the safety belt buckle bolt.
3 Remove the safety belt buckle.
NOTE: Clamp the safety belt buckle support assembly in a vise along the break line only.
INSTALLATION
WARNING:
^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT
BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF
SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING
HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES
SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES
SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A
COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR
IMPROPER OPERATION IS NOTED.
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT
IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced, the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system, the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9137
1. Install the safety belt buckle onto the safety belt buckle support assembly.
1 Position the safety belt buckle onto the safety belt buckle support assembly.
2 Using the special tool, install the safety belt buckle bolt.
3 Remove the safety belt buckle support assembly from the vise.
2. Install the safety belt buckle support assembly onto the seat.
1 Position the safety belt buckle support assembly to the seat.
2 Install the nut and bolt.
3. Position the passenger seat into the vehicle. Install and hand-tighten the four seat track to floor
bolts.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle can result in damaged components.
4. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9138
5. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 6.
Connect the battery ground cable. 7. Position the front seats rearward. 8. With the restraint system
diagnostic tools still in place at the remaining deployable devices, prove out the air bag system.
9. Tighten in sequence the passenger seat front track-to-floor bolts.
1 Tighten to specification the front inboard bolt.
2 Tighten to specification the front outboard bolt.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ HE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Tighten in sequence the passenger seat rear track-to-floor bolts.
1 Tighten to specification the rear inboard bolt.
2 Tighten to specification the rear outboard bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9139
13. Install the passenger seat rear track bolt covers.
14. Using the special tool, install the safety belt buckle support assembly bolt.
15. Install the safety belt buckle support assembly bolt cover.
16. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9140
17. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 18.
Connect the battery ground cable. 19. Position the front seats rearward. 20. Disconnect the battery
ground cable and wait at least one minute.
21. Remove the restraint system diagnostic tool from the vehicle harness side of the air bag sliding
contact electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
22. Connect the air bag sliding contact electrical connector at the base of the steering column.
23. Position the lower steering column opening finish panel reinforcement and install the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9141
24. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
25. Position the hood release handle and install the screws.
26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
27. Install the passenger air bag module. 28. Connect the battery ground cable. 29. With all the
diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
30. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Seats Without Side Air Bag > Page 9142
Seat Belt Buckle: Service and Repair Rear Seat
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Remove the rear seats.
2. Remove the rear safety belt buckles.
1 Remove the nuts.
2 Remove the rear safety belt buckles.
INSTALLATION
1. To install, reverse the removal procedure.
^ Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Page 9143
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9151
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9152
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9153
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9154
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9155
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9156
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9157
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information >
Description and Operation
Seat Belt Extension: Description and Operation
Safety Belt Extension Assembly
In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in)
can be added to the belt length by using a safety belt extension. Safety belt extensions are
available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt
extensions are only available with black webbing.
There are two extension assemblies available, one for the front seating positions and one for the
rear seating positions, and they are not interchangeable.
Use only extensions manufactured by the same supplier of the safety belt. Manufacturer
identification is located at the end of the webbing on the label. Also, use the safety belt extension
only if the safety belt is too short for the occupant when fully extended. Do not use an extension to
change the fit of the shoulder belt across the torso.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Specifications
Seat Belt Height Adjuster: Specifications
Safety Belt Shoulder Height Adjuster Bolts 40 Nm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Removal and Installation
Seat Belt Height Adjuster: Service and Repair Removal and Installation
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
1. Remove the quarter trim panel.
2. Remove the height adjuster cover.
3. Remove the shoulder safety belt height adjuster.
1 Using the special tool, remove the two bolts.
2 Remove the shoulder safety belt height adjuster.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Removal and Installation > Page 9166
Seat Belt Height Adjuster: Service and Repair General Procedures
D-Ring Installation Kit
SPECIAL TOOL(S)
1. Remove the B-pillar trim panel.
2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the
damaged threads in the upper pillar structure.
3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation
Kit and tap new threads.
NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any
chips before proceeding.
4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into
the retapped hole until it is slightly below the
surface.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Removal and Installation > Page 9167
5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several
times to seat the insert keys.
NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Page 9168
Seat Belt Height Adjuster: Tools and Equipment
Seat Belt Bolt Bit (Used For T-50 Head Bolt)
D-Ring Installation Kit
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Application and ID
Seat Belt Reminder Lamp: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts
Slow to Retract
Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract
TSB 05-16-11
08/22/05
SAFETY BELT RETRACTION SPEED
FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport,
Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty,
Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape
Hybrid 2004-2006 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator
MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006
Monterey 2005-2006 Mariner
This article supersedes TSB 04-24-21 to update the vehicle model years.
ISSUE A service kit is now available to improve safety belt retraction speed.
ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet
included in the kit. Refer to Workshop Manual Section 501-20A for additional information.
NOTE
TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES
LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE
MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE
THREE VEHICLES.
NOTE
FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE
FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE
HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES.
^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on
vehicles built on/after 6/16/2003.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles
built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles
built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts
Slow to Retract > Page 9180
Parts Block
NOTE
THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS
NEEDED TO COVER THE REQUIRED REPAIRS.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051611A Install Teflon Tape B 0.8 Hr.
Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary)
051611B Install Teflon Tape C 1.1 Hrs.
Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary)
DEALER CODING
CONDITION
BASIC PART NO. CODE
70611B08 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract
Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract
TSB 05-16-11
08/22/05
SAFETY BELT RETRACTION SPEED
FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport,
Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty,
Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape
Hybrid 2004-2006 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator
MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006
Monterey 2005-2006 Mariner
This article supersedes TSB 04-24-21 to update the vehicle model years.
ISSUE A service kit is now available to improve safety belt retraction speed.
ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet
included in the kit. Refer to Workshop Manual Section 501-20A for additional information.
NOTE
TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES
LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE
MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE
THREE VEHICLES.
NOTE
FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE
FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE
HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES.
^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on
vehicles built on/after 6/16/2003.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles
built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles
built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 9186
Parts Block
NOTE
THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS
NEEDED TO COVER THE REQUIRED REPAIRS.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051611A Install Teflon Tape B 0.8 Hr.
Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary)
051611B Install Teflon Tape C 1.1 Hrs.
Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary)
DEALER CODING
CONDITION
BASIC PART NO. CODE
70611B08 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 9187
Seat Belt Retractor: Specifications
Rear Seat Center Occupant Safety Belt Retractor And Passenger Side Safety Belt Buckle
Assembly Bolt 40 Nm
Safety Belt Retractor Bolts 40 Nm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 9188
Seat Belt Retractor: Service Precautions
WARNING:
^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT
BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF
SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING
HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES
SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES
SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A
COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR
IMPROPER OPERATION IS NOTED.
^ AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD
SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING
RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERITY
THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL
FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT
SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE
SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY
OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED
ACCORDING TO THE PROCEDURES. FAILURE TO REPLACE THE BELT AND RETRACTOR
ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 9189
Seat Belt Retractor: Testing and Inspection
WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL
OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC
LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO
VERITY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS
STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY
BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF
THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY
OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED
ACCORDING TO THE PROCEDURES. FAILURE TO REPLACE THE BELT AND RETRACTOR
ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS.
1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in
the safety belt, with the seat in the full down and
rearmost position, seat back in an upright position, and if applicable, the O-ring adjusted in the full
down position.
2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor
(ALR) feature. Then allow the belt to retract freely in
the ALR mode, and the retractor force set the correct belt tightness.
3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not
locked, install a new belt and retractor assembly.
The safety belt should remain locked in the ALR mode across an empty seat.
4. To verify that the safety belt still automatically disengages from the ALR mode correctly, with the
O-ring adjusted to the full up position, if
applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its
stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted
automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and
retractor assembly must be installed. The safety belt should extract freely.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor
Seat Belt Retractor: Service and Repair Front Safety Belt Retractor
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
All Vehicles
1. Pull to release the retaining clips and remove the windshield side garnish molding.
2. Pull up to release the retaining clips and remove the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9192
3. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
4. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
5. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 6.
Position the carpet aside at the front safety belt anchor.
7. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9193
8. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
3 Remove the quarter trim panel front screw.
9. Fold the rear seat into the load floor position.
10. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
11. Remove the retractable cargo cover.
All vehicles
12. Remove the rear safety belt guide.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9194
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
3 Remove the rear safety belt guide.
13. Position the carpet aside at the rear safety belt anchor.
14. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
15. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
16. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9195
17. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
Vehicles with a rear power lock switch
18. Through the jack access panel, release the rear power lock switch assembly retaining tab and
pull the switch through.
19. Disconnect and remove the rear power lock switch assembly.
All Vehicles
20. Remove the pin-type retainers from the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9196
21. Slide the quarter trim panel forward and disengage it from the door jamb.
22. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
23. Remove the safety belt web guide.
1 Remove the bolt.
2 Remove the safety belt web guide from the B-pillar.
24. Remove the front safety belt retractor.
1 Using the special tool, remove the bolt.
2 Remove the front safety belt retractor.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9197
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
All Vehicles
1. Install the front safety belt retractor.
1 Position the front safety belt retractor to the B-pillar.
2 Using the special tool, install the bolt.
NOTE: Make sure to tighten nuts and bolts to specification.
2. Install the safety belt web guide.
1 Position the safety belt web guide to the B-pillar.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
3. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbings through the openings in the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9198
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
4. Slide back and engage the edge of the quarter trim panel into the doorjamb.
5. Install the quarter trim panel rear screws.
6. Through the front door opening, install the quarter trim front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
7. Install the pin-type retainers into the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9199
8. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
9. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Vehicles with a rear power lock switch
10. Connect and install the rear power lock switch assembly into the rear quarter trim panel.
All Vehicles
11. Position the washer on the rear safety belt guide bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9200
12. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
13. Fold the rear seat into the load floor position.
14. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
15. Reposition the carpet back over the floor.
16. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo cover
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9201
17. Install the retractable cargo cover.
All Vehicles
18. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
19. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9202
20. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
21. Reposition the carpet at the front safety belt anchor.
22. Align the retaining clips and install the front door scuff plate.
23. Align the retaining clips and install the windshield side garnish molding. 24. Reposition the rear
seat back up. 25. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9203
Seat Belt Retractor: Service and Repair Rear Safety Belt Retractor
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
All Vehicles
1. Pull to release the retaining clips and remove the windshield side garnish molding.
2. Pull up to release the retaining clips and remove the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9204
3. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
4. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
5. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 6.
Position the carpet aside at the front safety belt anchor.
7. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9205
8. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
3 Remove the quarter trim panel front screw.
9. Fold the rear seat into the load floor position.
10. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
11. Remove the retractable cargo cover.
All Vehicles
12. Remove the rear safety belt guide.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9206
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
3 Remove the rear safety belt guide.
13. Position the carpet aside at the rear safety belt anchor.
14. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
15. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
16. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9207
17. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
Vehicles with rear power lock switch
18. Through the jack access panel, release the rear power lock switch assembly retaining tab and
pull the switch through.
19. Disconnect and remove the rear power lock switch assembly.
All Vehicles
20. Remove the pin-type retainers from the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9208
21. Slide the quarter trim panel forward and disengage it from the doorjamb.
22. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
23. Remove the rear safety belt retractor.
1 Using the special tool, remove the bolt.
2 Remove the rear safety belt retractor.
INSTALLATION
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
All Vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9209
1. Install the rear safety belt retractor.
1 Position the rear safety belt retractor to the B-pillar.
2 Using the special tool, install the bolt.
NOTE: Make sure to tighten nuts and bolts to specification.
2. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbings through the openings in the quarter trim panel.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
3. Slide back and engage the edge of the quarter trim panel into the door jamb.
4. Install the quarter trim panel rear screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9210
5. Through the front door opening, install the quarter trim panel front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim panel front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
6. Install the pin-type retainers into the quarter trim panel.
7. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
8. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9211
Vehicles with rear power lock switch
9. Connect and install the rear power lock switch assembly into the rear quarter trim panel.
All Vehicles
10. Position the washer on the rear safety belt guide bolt.
11. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
12. Fold the rear seat into the load floor position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9212
13. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
14. Reposition the carpet back over the floor.
15. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo covers
16. Install the retractable cargo cover.
All Vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9213
17. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
18. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
19. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
20. Reposition the carpet at the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 9214
21. Align the retaining clips and install the front door scuff plate.
22. Align the retaining clips and install the windshield side garnish molding. 23. Reposition the rear
seat back up. 24. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Page 9215
Seat Belt Bolt Bit (Used For T-50 Head Bolt)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information >
Technical Service Bulletins > Seat Belts - Warning System Operation
Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation
Article No. 01-2-5
2/05/01
^ TRIM - SEAT BELT WARNING SYSTEM - "BELT
^ MINDER" FUNCTION - OPERATION AND SERVICE
^ TIPS
^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND
^ SERVICE TIPS
FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION,
F-150, RANGER, WINDSTAR 2001 EXPLORER
LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR
MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER
ISSUE
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning
function. This feature provides additional reminders to the driver that the driver's safety belt is
unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the
instrument cluster.
ACTION
Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by
performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt
Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following
Service Procedure.
SERVICE PROCEDURE
To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure.
1. Establish a session for the vehicle.
2. Select the "Toolbox" icon.
3. Select "Module Programming" and press the "Tick" mark.
4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark.
5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark.
6. WDS will display "Configuration Complete", then press the "Tick" mark.
NOTE:
IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT
LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH
HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT
WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS
EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE
SAFETY BELT IS BUCKLED.
NOTE:
WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND
CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT
WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND
FOR 4-8 SECONDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information >
Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9220
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 104000, 204000, 206000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information >
Technical Service Bulletins > Seat Belts - Warning System Operation
Seat Belt Warning Timer: Technical Service Bulletins Seat Belts - Warning System Operation
Article No. 01-2-5
2/05/01
^ TRIM - SEAT BELT WARNING SYSTEM - "BELT
^ MINDER" FUNCTION - OPERATION AND SERVICE
^ TIPS
^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND
^ SERVICE TIPS
FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION,
F-150, RANGER, WINDSTAR 2001 EXPLORER
LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR
MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER
ISSUE
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning
function. This feature provides additional reminders to the driver that the driver's safety belt is
unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the
instrument cluster.
ACTION
Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by
performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt
Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following
Service Procedure.
SERVICE PROCEDURE
To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure.
1. Establish a session for the vehicle.
2. Select the "Toolbox" icon.
3. Select "Module Programming" and press the "Tick" mark.
4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark.
5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark.
6. WDS will display "Configuration Complete", then press the "Tick" mark.
NOTE:
IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT
LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH
HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT
WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS
EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE
SAFETY BELT IS BUCKLED.
NOTE:
WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND
CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT
WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND
FOR 4-8 SECONDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information >
Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9225
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 104000, 204000, 206000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information >
Technical Service Bulletins > Page 9226
Seat Belt Warning Timer: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information >
Technical Service Bulletins > Page 9227
Seat Belt Warning Timer: Description and Operation
Safety Belt Warning Indicator and Chime
The warning indicator and chime are reminders to fasten the safety belt. The following conditions
will take place: ^
If the safety belt is not buckled before the ignition is turned to the ON position, the chime will turn
on for four to eight seconds and the indicator will come on for one to two minutes.
^ If the safety belt is buckled while the indicator is on and the chime is sounding, both the indicator
and chime will turn off.
^ If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator
nor the chime will turn on.
Belt Minder (if equipped)
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently
sounding a chime and illuminating the safety belt warning lamp in the instrument cluster.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Specifications
Impact Sensor: Specifications
Side Crash Sensor Bolts 12 Nm
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Locations Views
Impact Sensor: Locations Locations Views
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 1 Of 2
Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport, Part 2 Of 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Locations Views > Page 9234
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Locations Views > Page 9235
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Right
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Right > Page 9238
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR
CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN
WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND
BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER
OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE
RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service Precautions > Customer Safety Information > Page 9241
Impact Sensor: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS
CRITICAL FOR PROPER SYSTEM OPERATION.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service Precautions > Page 9242
Impact Sensor: Description and Operation
WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR
CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN
WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND
BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER
OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE
RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
The SRS contains two sensors which are integral to the RCM. The RCM is mounted on the center
tunnel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation
Impact Sensor: Service and Repair Removal and Installation
Side Crash Sensor, Driver Side
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9245
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the retaining screws and position the hood release handle out of the way.
3. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9246
4. Remove the bolts and the lower steering column opening finish panel reinforcement.
5. Disconnect the clockspring electrical connector at the base of the steering column.
6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 7. Remove the passenger air bag module.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9247
SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR
STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS
DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD
LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9248
15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the
diagnostic tools in place at all deployable devices, prove out the air bag system. See: Air Bag
Systems/Air Bag(s) Arming and Disarming 19. Position the front seats to their most forward
position. 20. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
21. Pull to release the retaining clips and remove the windshield side garnish molding.
22. Pull up to release the retaining clips and remove the front door scuff plate.
23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9249
24. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26.
Position the carpet aside at the front safety belt anchor.
27. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
28. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9250
3 Remove the quarter trim panel front screw.
29. Fold the rear seat into the load floor position.
30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
31. Remove the retractable cargo cover.
All Vehicles
32. Remove the rear safety belt guide.
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
3 Remove the rear safety belt guide.
33. Position the carpet aside at the rear safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9251
34. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
35. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
36. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
37. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9252
38. Remove the pin-type retainers from the quarter trim panel.
39. Slide the quarter trim panel forward and disengage it from the door jamb.
40. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness
out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9253
42. Position the side crash sensor with bracket away from the B-pillar.
1 Remove the bolts.
2 Position the side crash sensor with bracket away from the B-pillar.
43. Remove the side crash sensor.
1 Disconnect the electrical connector.
2 Remove the side crash sensor.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9254
removed from the vehicle and the restraint system diagnostic tools must be installed in the side
airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The
restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Connect the side crash sensor electrical connector.
1 Position the side crash sensor.
2 Connect the side crash sensor electrical connector.
2. Install the side crash sensor.
1 Position the side crash sensor with the bracket to the B-pillar.
2 Install the bolts.
WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery
ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all
deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest
and most forward position. 8. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9255
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
9. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbings through the openings in the quarter trim panel.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
10. Slide back and engage the edge of the quarter trim panel into the door jamb.
11. Install the quarter trim panel rear screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9256
12. Through the front door opening, install the quarter trim panel front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim panel front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
13. Install the pin-type retainers into the quarter trim panel.
14. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
15. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Vehicles with a rear power lock switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9257
16. Connect and install the rear power lock switch assembly into the rear quarter trim panel.
All vehicles
17. Position the washer on the rear safety belt guide bolt.
18. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
19. Fold the rear seat into the load floor position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9258
20. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
21. Reposition the carpet back over the floor.
22. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo covers
23. Install the retractable cargo cover.
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9259
24. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
25. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
26. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
27. Reposition the carpet at the front safety belt anchor.
28. Align the retaining clips and install the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9260
29. Align the retaining clips and install the windshield side garnish molding. 30. Reposition the rear
seat back upward.
31. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
32. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
33. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9261
VEHICLE SAFETY STANDARDS.
34. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 35.
Connect the battery ground cable. 36. Position the front seats rearward. 37. Disconnect the battery
ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
38. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
39. Install the passenger air bag module.
40. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9262
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
41. Connect the clockspring electrical connector at the base of the steering column.
42. Position the lower steering column opening finish panel reinforcement and install the bolts.
43. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
44. Position the hood release handle and install the screws. 45. Connect the battery ground cable.
46. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air
Bag(s) Arming and Disarming
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9263
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
47. Check the restraint system for correct operation.
Side Crash Sensor, Passenger Side
Special Tool(s)
SPECIAL SERVICE TOOL(S)
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE
INSTALLED NEW, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9264
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All Vehicles
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
2. Remove the passenger air bag module.
3. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
4. Remove the retaining screws and position the hood release handle out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9265
5. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
6. Remove the bolts and the lower steering column opening finish panel reinforcement.
7. Disconnect the clockspring electrical connector at the base of the steering column.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 9. Connect the battery ground cable.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9266
DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING,
REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR
BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES,
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
14. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9267
15. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the
diagnostic tools in place at all deployable devices, prove out the air bag system. See: Air Bag
Systems/Air Bag(s) Arming and Disarming 19. Position the front seats to their most forward
position. 20. Disconnect the battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
21. Pull to release the retaining clips and remove the windshield side garnish molding.
22. Pull up to release the retaining clips and remove the front door scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9268
23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover.
NOTE: The front safety belt guide has been removed for clarity.
24. Remove the front safety belt guide.
1 Using the special tool, remove the front safety belt guide bolt.
2 Remove the front safety belt guide.
25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26.
Position the carpet aside at the front safety belt anchor.
27. Remove the front safety belt anchor.
1 Using the special tool, remove the front safety belt anchor bolt.
2 Remove the front safety belt anchor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9269
28. Through the front door opening, remove the quarter trim panel front screw.
1 Position the rear seat back part of the way down (the seat back bar is shown).
2 Peel the carpet back between the rear seat and the quarter trim panel.
3 Remove the quarter trim panel front screw.
29. Fold the rear seat into the load floor position.
30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate.
Vehicles with retractable cargo cover
31. Remove the retractable cargo cover.
All Vehicles
32. Remove the rear safety belt guide.
1 Peel the rear safety belt guide cover down.
2 Using the special tool, remove the rear safety belt guide bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9270
3 Remove the rear safety belt guide.
33. Position the carpet aside at the rear safety belt anchor.
34. Remove the rear safety belt anchor.
1 Using the special tool, remove the rear safety belt anchor bolt.
2 Remove the rear safety belt anchor.
35. Remove the quarter trim panel rear screws.
^ Position the carpet aside to gain access to the screws.
36. Position the rear quarter window latch out of the way.
1 Remove the two rear quarter window latch screws.
2 Position the rear quarter window latch out of the way.
37. Remove the coat hook.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9271
1 Remove the screw.
2 Remove the coat hook.
38. Remove the pin-type retainers from the quarter trim panel.
39. Slide the quarter trim panel forward and disengage it from the door jamb.
40. Remove the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Remove the quarter trim panel.
41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness
out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9272
42. Position the side crash sensor with the bracket away from the B-pillar.
1. Remove the bolts. 2. Position the side crash sensor with the bracket away from the B-pillar.
43. Remove the side crash sensor.
1 Disconnect the electrical connector.
2 Remove the side crash sensor.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM(SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9273
removed from the vehicle and the restraint system diagnostic tools must be installed in the side
airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The
restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles
1. Connect the side crash sensor electrical connector.
1 Position the side crash sensor.
2 Connect the side crash sensor electrical connector.
2. Install the side crash sensor.
1 Position the side crash sensor with the bracket to the B-pillar.
2 Install the bolts.
WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING
BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery
ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all
deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest
and most forward position. 8. Disconnect the battery ground cable and wait at least one minute.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9274
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS. NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
9. Position the quarter trim panel into the vehicle.
1 Position the quarter trim panel into the vehicle.
2 Route the front and rear safety belt webbing through the openings in the quarter trim panel.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
10. Slide back and engage the edge of the quarter trim panel into the door jamb.
11. Install the quarter trim panel rear screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9275
12. Through the front door opening, install the quarter trim panel front screw.
1 Position the rear seat back part of the way up (the seat back bar shown).
2 Install the quarter trim panel front screw.
3 Reposition the carpet back between the rear seat and the quarter trim panel.
13. Install the pin-type retainers into the quarter trim panel.
14. Install the rear quarter window latch.
1 Position the rear quarter window latch.
2 Install the two screws.
15. Install the coat hook.
1 Position the coat hook.
2 Install the screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9276
16. Position the washer on the rear safety belt guide bolt.
17. Install the rear safety belt guide.
1 Position the rear safety belt guide.
2 Using the special tool, install the rear safety belt guide bolt.
3 Reposition the rear safety belt guide cover around the safety belt guide.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
18. Fold the rear seat into the load floor position.
19. Install the rear safety belt anchor.
1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot.
2 Install the bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
20. Reposition the carpet back over the floor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9277
21. Align the retaining clips and install the liftgate scuff plate.
Vehicles with retractable cargo covers
22. Install the retractable cargo cover.
All Vehicles
23. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the
retaining tabs.
NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
24. Install the front safety belt guide.
1 Position the front safety belt guide.
2 Using the special tool, install the front safety belt guide bolt.
3 Close the front safety belt guide bolt cover.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9278
^ Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover.
25. Install the front safety belt anchor.
1 Position the front safety belt retractor.
2 Using the special tool, install the front safety belt anchor bolt.
NOTE: ^
Make sure the safety belt webbing is not twisted prior to installation.
^ Make sure to tighten nuts and bolts to specification.
26. Reposition the carpet at the front safety belt anchor.
27. Align the retaining clips and install the front door scuff plate.
28. Align the retaining clips and install the windshield side garnish molding. 29. Reposition the rear
seat back upward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9279
30. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
31. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
32. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
33. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9280
34. Connect the battery ground cable. 35. Position the front seats rearward. 36. Disconnect the
battery ground cable and wait at least one minute.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
37. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
38. Connect the clockspring electrical connector at the base of the steering column.
39. Position the lower steering column opening finish panel reinforcement and install the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9281
40. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
41. Position the hood release handle and install the screws.
42. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
43. Install the passenger air bag module. 44. Connect the battery ground cable. 45. With all the
diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming
and Disarming
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
46. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9282
Impact Sensor: Service and Repair General Procedures
"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control
Module (RCM) and Side Crash Sensor before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut
Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts
must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and
Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification. Refer to Torque Specifications.
Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM)
and Side Crash Sensor before proceeding with the repair.
^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld
Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-S190).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 9283
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification. Refer to Torque Specifications.
Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE
LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Refer to Torque Specifications.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Page 9284
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag >
Component Information > Description and Operation
Safing Sensor: Description and Operation
The safing sensor is internal to the RCM and is not serviced separately.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair
Antenna Cable: Service and Repair
REMOVAL
NOTE: Antenna lead-in runs from audio unit to connector behind glove box.
1. Remove the audio unit.
2. Remove the antenna lead-in cable.
1 Open the glove box door.
2 Release the tabs and lower the glove box door to the full open position.
3 Release the antenna lead-in cable clips.
4 Disconnect the connector.
5 Separate the antenna cable from the lead-in cable and remove the lead-in cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Passive Anti-Theft Transceiver
Alarm System Transponder: Diagrams Passive Anti-Theft Transceiver
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Passive Anti-Theft Transceiver > Page 9305
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Page 9306
Alarm System Transponder: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, remove the tilt wheel handle.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Page 9307
5. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
6. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the bolts.
2 Remove the instrument panel steering column opening cover reinforcement.
7. Remove the anti-theft transceiver module.
1 Remove the screw from the bottom of the transceiver module.
2 Disconnect the electrical connector and remove the module.
NOTE: ^
The steering wheel has been removed for clarity.
^ Only apply pressure or leverage below the key cylinder lower rib.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics
Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics
TSB 06-15-8
08/07/06
KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY
FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005
Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006
Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006
F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005
Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar
LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator
2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT
MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan
1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner
ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to
properly diagnose the concern with the keyless entry keypad, it is important to identify whether the
keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF)
style keypad.
ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic
service tips.
SERVICE PROCEDURE
IDENTIFICATION:
1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and
are wired directly to the module controlling the vehicle's keyless entry system. This style keypad
can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9313
2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13
mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM
(Figure 1).
NOTE
THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES
BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD
DIAGNOSTICS FOR THESE VEHICLES.
GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS
1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed
using a similar procedure.
Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter
programming portion of the WSM, Section 501-14 can be used as a guide
NOTE
THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY
DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN
ADDITIONAL REMOTE TRANSMITTER.
Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic
pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the
lock / unlock functions will differ
2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced
separately.
3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be
replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super
Duty vehicles produced prior to 12/3/2003).
4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by
vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is
replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM
etc.) is replaced.
NOTE
THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED
KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR
VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN
THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME
ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING
PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD
SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL
CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE.
5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the
illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all
doors). The keypad contains an optical sensor and will not illuminate under bright lighting
conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the
battery power available to transmit a lock/unlock signal. The temperature at which this occurs will
vary depending upon the keypad battery age and condition. Both of these conditions are a normal
function of the Power Save Mode and do not indicate a need to replace the keypad.
6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it
again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication
that battery power is very low and the keypad must be replaced.
7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35
consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash
during this time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9314
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A626 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9315
Keyless Entry Key-Pad: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9316
Keyless Entry Key-Pad: Service and Repair
REMOVAL
1. Remove the front door speaker.
2. Disconnect the keyless entry electrical connector.
3. Remove the two wiring harness locators.
4. Release the retaining clip.
5. Remove the key less entry keypad.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Locations
Keyless Entry Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9322
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9323
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9324
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9325
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9326
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9327
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9328
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9329
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9330
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9331
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9332
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9333
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9334
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9335
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9336
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9337
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9338
Keyless Entry Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9339
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9340
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9341
Keyless Entry Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9342
Keyless Entry Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Page 9343
Keyless Entry Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Locations > Central Security Module
Multifunction Electronic Control Modules: Locations Central Security Module
Vehicles Built AFTER 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Locations > Central Security Module > Page 9348
Multifunction Electronic Control Modules: Locations Generic Electronic Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Locations > Central Security Module > Page 9349
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Locations > Central Security Module > Page 9350
Multifunction Electronic Control Modules: Locations Remote Anti-Theft Personality Module
Vehicles Built BEFORE 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions
Multifunction Electronic Control Modules: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9353
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9354
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9355
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9356
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9357
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9358
Sample Diagrams
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9359
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9360
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9361
Circuit Identification Chart
SYSTEM CODES CHART
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9362
SAMPLE DIAGRAMS
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9363
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9364
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9365
Symbols
Symbols
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9366
Symbols
Symbols
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9367
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9368
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9369
Multifunction Electronic Control Modules: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9370
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9371
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9372
Multifunction Electronic Control Modules: Connector Views
Central Security Module
Vehicles Built AFTER 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9373
Generic Electronic Module
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9374
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9375
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9376
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9377
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9378
Remote Anti-Theft Personality Module
Vehicles Built BEFORE 7/24/2000
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9379
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9380
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9381
Multifunction Electronic Control Modules: Electrical Diagrams
Diagram 419-10-00-1
Diagram 419-10-00-2
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9382
Diagram 419-10-00-3
Diagram 419-10-00-4
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Page 9383
Multifunction Electronic Control Modules: Service Precautions
CAUTION:
^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module
configuration information to the diagnostic tool. This information needs to be downloaded into, the
new module once installed.
^ Once the new module is installed, it is necessary to download module configuration information
from the appropriate diagnostic tool into the new module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Description and Operation > System Description
Multifunction Electronic Control Modules: Description and Operation System Description
Module Controlled Functions
NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module
configuration information to a diagnostic tool. This information needs to be downloaded into the
new module once installed.
The multifunction module consists of the following:
^ Generic Electronic Module (GEM)
^ Remote Anti-theft Personality (RAP) module (vehicles built before 7/24/2000)
^ central security module (vehicles built after 7/24/2000)
The GEM controls the following features: ^
front wiper and washer
^ rear wiper and washer
^ warning chime
^ battery saver
^ illuminated entry and interior lighting
^ driver one-touch down power window (optional)
^ battery saver relay
^ door ajar warning indicator lamp
^ safety belt warning indicator lamp
The remote anti-theft personality (RAP)/central security module controls the following features: ^
remote keyless entry
^ computer-operated locks
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Module] > Component Information > Description and Operation > System Description > Page 9386
Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How
Does It Work?)
Central Security Module
The central security module controls the following features:
^ remote key less entry system
^ computer-operated lock system
Generic Electronic Module (Gem)
NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be
reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal.
The GEM receives inputs and delivers outputs to a majority of the electronically controlled features
of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in
the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool
through the ISO 9141 communication network. The GEM controls the following features:
^ front wiper and washer
^ warning chime
^ battery saver
^ illuminated entry and interior lighting
^ driver one-touch down power window (optional)
^ battery saver relay
^ door ajar warning indicator lamp
^ safety belt warning indicator lamp
Remote Anti-Theft Personality (RAP) Module
The Remote Anti-theft Personality (RAP) module controls the following features:
^ remote keyless entry system
^ computer-operated lock system
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview
Central Security Module (CSM)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 18 (25 A)
- 11 (7.5 A)
^ Wiring harness Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module
Communications Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the central security module.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Generic Electronic Module (GEM)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 10 (7.5A)
- 20 (7.5A)
- 25 (7.5A)
- 28 (7.5A)
^ Wiring harness
^ Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module
Communications Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the GEM.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Remote Anti-Theft Personality (RAP) Module
1. Verify the customer concern by operating the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9389
2. Visually inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 18 (25A)
- 11 (7.5A)
^ Wiring harness
^ Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications
Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test C.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the central security module.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9390
Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated
Procedures
DTC Chart B1213 - B1322
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9391
DTC Chart B1322 - B1345
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9392
DTC Chart B1347 - B1450
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9393
DTC Chart B1453 - B1602
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9394
DTC Chart B1610 - B1932
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9395
DTC Index B1933 - B2477
DTC Index B2477 - C1230
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9396
C1233 - P1826
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9397
P1827 - U2018
..
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9398
Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures
Symptom Chart
Symptom Chart
Symptom Chart
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9399
Multifunction Electronic Control Modules: Pinpoint Tests
B1
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Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9400
B1 - B2
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9401
A1 - A2
A2
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9402
C1
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9403
C1 - C2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Service and Repair > Central Security Module
Multifunction Electronic Control Modules: Service and Repair Central Security Module
REMOVAL
CAUTION: Prior to removal of the module, it is necessary to upload module configuration
information to the appropriate diagnostic equipment. This information needs to be downloaded into
the new module once installed.
1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel.
3. Disconnect the electrical connectors.
4. Remove the central security module.
1 Remove the bolts.
2 Remove the central security module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Service and Repair > Central Security Module > Page 9406
Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP)
Module
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel.
3. Disconnect the electrical connectors.
4. Remove the RAP module.
1 Remove the bolts.
2 Remove the RAP module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Service and Repair > Central Security Module > Page 9407
Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload
module configuration information to the diagnostic tool. This information needs to be downloaded
into, the new module once installed.
2. Remove the radio chassis. Refer to Radio, Stereo, and Compact Disc.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
4. Remove the GEM.
1 Remove the bolt.
2 Disconnect the electrical connectors from the GEM.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download module configuration
information from the appropriate diagnostic tool into the new module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Service and Repair > Page 9408
Multifunction Electronic Control Modules: Tools and Equipment
Special Tool(s)
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9422
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9423
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9424
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9425
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9426
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9427
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9428
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio
Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9434
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9435
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9436
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9437
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9438
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9439
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9440
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Diagrams > Page 9444
Remote Control: Service and Repair
REMOVAL
1. Disconnect the battery.
2. Remove the console compartment trim panel screws.
3. Remove the console compartment door hinge screw.
4. Remove the console rear panel screws at the top of the panel.
5. Remove the console rear panel screws at the cup holder.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Diagrams > Page 9445
6. Remove the rear integrated control panel screws.
7. Disconnect the floor/panel control arm at the control head.
8. Disconnect the rear blower motor control and rear radio controls electrical connectors.
INSTALLATION
1. To install, reverse removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers
Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9454
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9455
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9456
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9457
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9458
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9459
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9460
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers
Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9466
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9467
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9468
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9469
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9470
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9471
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9472
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Page 9473
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Left
Speaker: Diagrams Left
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Left > Page 9476
Speaker: Diagrams Right
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 9477
Speaker: Description and Operation
All vehicles are equipped with four premium radio speakers and an optional subwoofer mounted in
the right rear quarter panel. The front speakers are mounted in the front doors. The rear speakers
are mounted in the rear quarter panels.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Mounted Speakers
Speaker: Service and Repair Door Mounted Speakers
REMOVAL
1. Remove the front door trim panels.
2. Remove the speakers.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the speakers.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Mounted Speakers > Page 9480
Speaker: Service and Repair Subwoofer Speaker
REMOVAL
1. Remove the quarter trim panel.
2. Remove the subwoofer.
1 Disconnect the electrical connector.
2 Remove the screws.
3 Remove the subwoofer.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations >
Central Security Module
Multifunction Electronic Control Modules: Locations Central Security Module
Vehicles Built AFTER 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations >
Central Security Module > Page 9489
Multifunction Electronic Control Modules: Locations Generic Electronic Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations >
Central Security Module > Page 9490
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations >
Central Security Module > Page 9491
Multifunction Electronic Control Modules: Locations Remote Anti-Theft Personality Module
Vehicles Built BEFORE 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions
Multifunction Electronic Control Modules: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9494
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9495
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9496
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9497
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9498
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9499
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9500
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9501
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9502
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9503
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9504
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9505
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9506
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9507
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9508
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9509
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9510
Multifunction Electronic Control Modules: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9511
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9512
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9513
Multifunction Electronic Control Modules: Connector Views
Central Security Module
Vehicles Built AFTER 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9514
Generic Electronic Module
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9515
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9516
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9517
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9518
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9519
Remote Anti-Theft Personality Module
Vehicles Built BEFORE 7/24/2000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9520
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9521
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9522
Multifunction Electronic Control Modules: Electrical Diagrams
Diagram 419-10-00-1
Diagram 419-10-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9523
Diagram 419-10-00-3
Diagram 419-10-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page
9524
Multifunction Electronic Control Modules: Service Precautions
CAUTION:
^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module
configuration information to the diagnostic tool. This information needs to be downloaded into, the
new module once installed.
^ Once the new module is installed, it is necessary to download module configuration information
from the appropriate diagnostic tool into the new module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and
Operation > System Description
Multifunction Electronic Control Modules: Description and Operation System Description
Module Controlled Functions
NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module
configuration information to a diagnostic tool. This information needs to be downloaded into the
new module once installed.
The multifunction module consists of the following:
^ Generic Electronic Module (GEM)
^ Remote Anti-theft Personality (RAP) module (vehicles built before 7/24/2000)
^ central security module (vehicles built after 7/24/2000)
The GEM controls the following features: ^
front wiper and washer
^ rear wiper and washer
^ warning chime
^ battery saver
^ illuminated entry and interior lighting
^ driver one-touch down power window (optional)
^ battery saver relay
^ door ajar warning indicator lamp
^ safety belt warning indicator lamp
The remote anti-theft personality (RAP)/central security module controls the following features: ^
remote keyless entry
^ computer-operated locks
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and
Operation > System Description > Page 9527
Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How
Does It Work?)
Central Security Module
The central security module controls the following features:
^ remote key less entry system
^ computer-operated lock system
Generic Electronic Module (Gem)
NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be
reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal.
The GEM receives inputs and delivers outputs to a majority of the electronically controlled features
of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in
the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool
through the ISO 9141 communication network. The GEM controls the following features:
^ front wiper and washer
^ warning chime
^ battery saver
^ illuminated entry and interior lighting
^ driver one-touch down power window (optional)
^ battery saver relay
^ door ajar warning indicator lamp
^ safety belt warning indicator lamp
Remote Anti-Theft Personality (RAP) Module
The Remote Anti-theft Personality (RAP) module controls the following features:
^ remote keyless entry system
^ computer-operated lock system
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview
Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview
Central Security Module (CSM)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 18 (25 A)
- 11 (7.5 A)
^ Wiring harness Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module
Communications Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the central security module.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Generic Electronic Module (GEM)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: -
10 (7.5A)
- 20 (7.5A)
- 25 (7.5A)
- 28 (7.5A)
^ Wiring harness
^ Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module
Communications Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the GEM.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Remote Anti-Theft Personality (RAP) Module
1. Verify the customer concern by operating the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9530
2. Visually inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 18 (25A)
- 11 (7.5A)
^ Wiring harness
^ Connector(s)
^ Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link
Connector (DLC) located beneath the instrument panel
and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not
communicate with the vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with:
^ CKT914, CKT915 or CKT70 ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications
Network (Information Bus).
^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test C.
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the central security module.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic
Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to
continue diagnostics.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9531
Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated
Procedures
DTC Chart B1213 - B1322
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9532
DTC Chart B1322 - B1345
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9533
DTC Chart B1347 - B1450
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9534
DTC Chart B1453 - B1602
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9535
DTC Chart B1610 - B1932
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9536
DTC Index B1933 - B2477
DTC Index B2477 - C1230
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9537
C1233 - P1826
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9538
P1827 - U2018
..
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9539
Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures
Symptom Chart
Symptom Chart
Symptom Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9540
Multifunction Electronic Control Modules: Pinpoint Tests
B1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9541
B1 - B2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9542
A1 - A2
A2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9543
C1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 9544
C1 - C2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair
> Central Security Module
Multifunction Electronic Control Modules: Service and Repair Central Security Module
REMOVAL
CAUTION: Prior to removal of the module, it is necessary to upload module configuration
information to the appropriate diagnostic equipment. This information needs to be downloaded into
the new module once installed.
1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel.
3. Disconnect the electrical connectors.
4. Remove the central security module.
1 Remove the bolts.
2 Remove the central security module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair
> Central Security Module > Page 9547
Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP)
Module
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel.
3. Disconnect the electrical connectors.
4. Remove the RAP module.
1 Remove the bolts.
2 Remove the RAP module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair
> Central Security Module > Page 9548
Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload
module configuration information to the diagnostic tool. This information needs to be downloaded
into, the new module once installed.
2. Remove the radio chassis. Refer to Radio, Stereo, and Compact Disc.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
4. Remove the GEM.
1 Remove the bolt.
2 Disconnect the electrical connectors from the GEM.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download module configuration
information from the appropriate diagnostic tool into the new module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair
> Page 9549
Multifunction Electronic Control Modules: Tools and Equipment
Special Tool(s)
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Locations
Keyless Entry Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9555
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9556
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9557
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9558
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9559
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9560
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9561
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9562
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9563
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9564
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9565
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9566
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9567
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9568
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9569
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9570
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9571
Keyless Entry Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9572
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9573
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9574
Keyless Entry Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9575
Keyless Entry Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9576
Keyless Entry Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Locations > Page 9581
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the trailer tow lamps. 2. Verify the exterior lighting
system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually
inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 3 (7.5A)
- 7 (7.5A)
- 36 (15A)
^ Circuitry
^ Trailer tow relay
^ Bulb(s)
4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart.
See: Symptom Related Diagnostic Procedures
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9586
Symptom Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9587
Trailer Lamps: Pinpoint Tests
Connector Circuit Reference
Refer to Vehicle/Diagrams for schematic and connector information.
V1
W1 - W2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9588
W2
X1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9589
X1
Y1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9590
Z1 - Z2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9591
Z2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9592
73III Automotive Meter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Page 9593
73III Automotive Meter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Page 9597
Trailer Lighting Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Page 9598
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations
> Page 9602
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair
Front Bumper Cover / Fascia: Service and Repair
FRONT BUMPER COVER
Removal and Installation
1. Remove the radiator grille sight shield.
1. Remove the bolts. 2. Release the retaining clips. 3. Remove the radiator grille sight shield.
2. Remove the two parking lamp assemblies.
1. Remove the two bolts (one each side). 2. Remove the two parking lamp assemblies.
- Disconnect the electrical connectors.
3. Remove the two headlamp assemblies.
1. Pull upward to release the four tabs (two each side). 2. Remove the two headlamp assemblies.
- Disconnect the electrical connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Page 9609
4. Remove the three lower radiator air deflector bolts.
5. Remove the six fender splash shield screws (three each side).
6. Remove the two front bumper cover bolts from inside the fender opening (one each side).
7. Remove the front bumper cover.
- Unclip the six locking tabs.
8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System
Information > Service and Repair
Front Bumper Reinforcement: Service and Repair
FRONT BUMPER
Removal and Installation
1. Remove the front bumper cover.
2. If equipped, remove the two fog lamp assemblies.
1. Disconnect the electrical connectors. 2. Remove the six bolts (three each side). 3. Remove the
two fog lamp assemblies.
3. WARNING: To avoid possible injury, support the front bumper before removing the nuts.
Remove the four nuts (two each side) and the front bumper.
4. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Bracket > System Information >
Service and Repair > 0102 Sport
Rear Bumper Bracket: Service and Repair 0102 Sport
BUMPER BRACKET - REAR, SPORT
Removal and Installation
1. Remove the rear bumper.
2. Remove the rear bumper bracket(s).
1. Remove the nuts and bolts. 2. Remove the bracket(s).
3. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Bracket > System Information >
Service and Repair > 0102 Sport > Page 9618
Rear Bumper Bracket: Service and Repair Sport
BUMPER BRACKET - REAR, SPORT
Removal and Installation
1. Remove the rear bumper.
2. Remove the rear bumper bracket(s).
1. Remove the nuts and bolts. 2. Remove the bracket(s).
3. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair
Rear Bumper Cover / Fascia: Service and Repair
REAR BUMPER COVER
Special Tool(s)
Special Tool(s)
Removal and Installation
1. Disconnect the two license plate lamps.
2. Remove the four splash shield screws (two each side).
3. Remove the two rear bumper cover rivets (one each side).
4. NOTE: Align the rear bumper cover to the rear bumper beam guide holes when installing the
step pads
Remove the two step pads (one each side).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Page 9622
5. Remove the rear bumper cover. 6. To install, reverse the removal procedure.
- Using the special tool, install the new rivets.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Disconnect the driver side windshield washer hose from inside the engine compartment.
2. Remove the windshield wiper pivot arms.
1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull
the windshield wiper pivot arm from the windshield wiper pivot shaft.
3. Remove the cowl grille screw.
4. Remove the driver side cowl grille.
- Pull up on the cowl grille to disengage the clips.
5. Remove the passenger side cowl grille.
- Pull up on the cowl grille to disengage the clips and disconnect the washer hose.
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
Heavy Duty Riveter
SPECIAL TOOL(S)
REMOVAL
NOTE: Front door shown, rear door similar.
1. Remove the door trim panel. 2. Position the watershield aside.
3. Disconnect the exterior handle actuating rod.
1 Open the clip.
2 Disconnect the exterior door handle actuating rod.
4. Remove the rivets and the exterior door handle.
INSTALLATION
1. To install, reverse the removal procedure.
- Using the special tool, install the rivets.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair > Page 9634
Heavy - Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Interior Handle > System Information > Service and Repair
Front Door Interior Handle: Service and Repair
REMOVAL
NOTE: Front door shown, rear door similar.
1. Remove the door trim panel. 2. Position the watershield aside.
3. Remove the interior door handle screws.
4. Remove the interior door handle.
1 Release the actuating rod.
2 Remove the interior door handle.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System
Information > Adjustments
Front Door Hinge: Adjustments
HINGE ADJUSTMENT - FRONT DOOR
NOTE:
- Check the rear door hinge adjustment before adjusting the front door hinge.
- Explorer Sport Trac shown Explorer Sport similar.
1. Remove the A-pillar lower trim panel.
2. Position the electrical connector mounting bracket aside.
1. Remove the pin-type retainer. 2. Position the electrical connector mounting bracket aside.
3. Mark the position of the front door hinges to use as a reference point.
4. NOTE: Position the front door to gain access to the bolts.
Loosen the two front door hinge to body bolts and nuts just enough to permit movement of the
door.
5. Adjust the front door alignment to specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System
Information > Adjustments > Page 9641
6. Tighten the front door hinge to body bolts and nuts.
7. Install the electrical connector mounting bracket.
1. Install the electrical connector mounting bracket. 2. Install the pin-type retainer.
8. Install the A-pillar lower trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Front
Front Door Latch: Service and Repair Front
SPECIAL TOOL(S)
Heavy Duty Riveter
REMOVAL
1. Remove the interior door handle.
2. Remove the door glass run channel.
1 Remove the bolt.
2 Remove the door glass run channel. Release the wiring harness locator.
3. Remove the screws and position the front door latch aside.
- Discard the screws.
4. Release the exterior door handle actuating rod.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Front > Page 9646
1 Open the clip.
2 Release the exterior door handle actuating rod.
5. Disconnect the front door lock cylinder rod.
6. If equipped, remove the door lock actuator rivet.
7. If equipped, disconnect the door lock actuator electrical connector.
8. Remove the front door latch.
1 Disconnect the door ajar switch electrical connector.
2 Disconnect the ground wire.
3 Remove the front door latch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Front > Page 9647
9. Remove the front door latch actuating rods.
1 Remove the door lock cylinder actuating rod.
2 Remove the push button lock actuating rod.
3 Remove the interior latch remote control actuating rod.
10. If equipped, remove the door lock actuator.
INSTALLATION
1. To install, reverse the removal procedure.
- Use the special tool to install the rivet.
- If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford
specification ESR-M1C159-A to lubricate the latches.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Front > Page 9648
Front Door Latch: Service and Repair Push Button Rod
Heavy Duty Riveter
SPECIAL TOOL(S)
REMOVAL
1. Remove the rear door latch.
2. Remove the rear door push button rod remote control.
1 Remove the rivet.
2 Release the clip and remove the rear door push button rod remote control.
3. Remove the push button rod.
1 Open the Clip.
2 Remove the push button rod.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Page 9649
Heavy Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair
Front Door Panel: Service and Repair
FRONT DOOR TRIM PANEL
Removal and Installation
High Series Door Trim Panels
1. Disconnect the battery ground cable.
2. Remove the front door window control switch panel.
- Disconnect the electrical connectors.
All Door Trim Panels
3. Remove the door handle cup screws.
4. Remove the door handle cup.
Low Series Door Trim Panels
5. Remove the screw and the window regulator handle.
All Door Trim Panels
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair > Page 9653
6. Remove the front door trim panel.
1. Remove the screws. 2. Remove the front door trim panel. If equipped, disconnect the exterior mirror control switch electrical connector.
7. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Service and Repair
Front Door Window Glass: Service and Repair
Heavy Duty Riverter
SPECIAL TOOL(S)
REMOVAL
1. Remove the front door trim panel.
2. Remove the front door belt line moulding.
1 Remove the nut.
2 Remove the moulding.
CAUTION: Do not strike or force the front door belt line moulding during installation. The front door
belt line moulding is made of aluminum and will be damaged.
NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge
of the sheet metal and the door panel shelf.
3. Remove the interior glass weatherstrip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Service and Repair > Page 9657
4. Remove the front door window glass rivets.
NOTE: Lower the window glass to access the rivets.
5. Remove the front door window glass through the outboard side of the front door.
INSTALLATION
1. To install, reverse the removal procedure.
^ Use the special tool to install the rivets.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Left Front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Left Front > Page 9662
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Page 9663
Front Door Window Motor: Service Precautions
CAUTION: Use care not to damage the drum housing when removing the rear window glass motor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Page 9664
Front Door Window Motor: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Remove the front door speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
3. Remove the water shield.
4. Disconnect the front door window regulator motor electrical connector.
5. Drill a 13 mm (0.52 in) hole using the locator in the door sheet metal as a guide.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Page 9665
6. Remove the bolts and the front door window regulator motor.
INSTALLATION
1. To install, reverse the removal procedure.
^ Cycle the door glass to make sure of engagement of the drive mechanism.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair
Front Door Window Regulator: Service and Repair
Heavy Duty Riverter
SPECIAL TOOL(S)
REMOVAL
1. Raise the front door window glass to the full up position. 2. Remove the interior door handle. 3.
Support the front door window glass.
4. Disconnect the front door window regulator motor electrical connector.
5. Remove the equalizer bracket nuts.
6. Remove the front door window regulator.
1 Remove the rivets.
2 Remove the nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 9669
7. Remove the front door window regulator motor.
1 Remove the bolts.
2 Remove the front door window regulator motor.
INSTALLATION
1. To install, reverse the removal procedure.
^ Use the special tool to install the rivets.
^ Cycle the door glass to make sure of engagement of the drive mechanism.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 9670
Heavy Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Exterior Handle > System Information > Service and Repair
Rear Door Exterior Handle: Service and Repair
Heavy Duty Riveter
SPECIAL TOOL(S)
REMOVAL
NOTE: Front door shown, rear door similar.
1. Remove the door trim panel. 2. Position the watershield aside.
3. Disconnect the exterior handle actuating rod.
1 Open the clip.
2 Disconnect the exterior door handle actuating rod.
4. Remove the rivets and the exterior door handle.
INSTALLATION
1. To install, reverse the removal procedure.
- Using the special tool, install the rivets.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Interior Handle > System Information > Service and Repair
Rear Door Interior Handle: Service and Repair
REMOVAL
NOTE: Front door shown, rear door similar.
1. Remove the door trim panel. 2. Position the watershield aside.
3. Remove the interior door handle screws.
4. Remove the interior door handle.
1 Release the actuating rod.
2 Remove the interior door handle.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System
Information > Adjustments
Rear Door Hinge: Adjustments
HINGE ADJUSTMENT - REAR DOOR
1. Remove the front seat safety belt retractor.
2. Mark the position of the rear door hinges to use as a reference point.
3. Loosen the rear door hinge to body nuts just enough to permit movement of the door.
4. Adjust the rear door alignment to specification.
5. Tighten the rear door hinge to body nuts. 6. Check the front door adjustments. 7. Install the front
seat safety belt retractor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Push Button Rod
Rear Door Latch: Service and Repair Push Button Rod
Heavy Duty Riveter
SPECIAL TOOL(S)
REMOVAL
1. Remove the rear door latch.
2. Remove the rear door push button rod remote control.
1 Remove the rivet.
2 Release the clip and remove the rear door push button rod remote control.
3. Remove the push button rod.
1 Open the Clip.
2 Remove the push button rod.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Push Button Rod > Page 9686
Rear Door Latch: Service and Repair Rear
Heavy Duty Riveter
SPECIAL TOOL(S)
REMOVAL
1. Remove the interior door handle.
2. Disconnect the push button actuating rod.
1 Release the Clip.
2 Disconnect the push button actuating rod.
3. Disconnect the exterior door handle actuating rod.
1 Open the clip.
2 Disconnect the exterior door handle actuating rod.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Push Button Rod > Page 9687
4. Remove the rear door latch screws.
- Discard the screws.
5. If equipped, remove the rear door lock actuator rivets.
- Disengage the wiring harness locator.
6. If equipped, disconnect the rear door lock actuator electrical connector.
7. Remove the rear door latch.
1 Disconnect the door ajar switch electrical connector.
2 Disconnect the ground wire.
8. Disconnect the rear door latch actuating rods.
1 Disconnect the interior door handle actuating rod.
2 If equipped, remove the door lock actuator.
INSTALLATION
1. To install, reverse the removal procedure.
- Use the special tool to install the rivets.
- If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford
specification ESR-M1C159-A to lubricate the latches.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Page 9688
Heavy Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair
Rear Door Panel: Service and Repair
REAR DOOR TRIM PANEL
Removal and Installation
High Series Door Trim Panels
1. Remove the rear door window control switch panel.
- Disconnect the electrical connector.
All Door Trim Panels
2. Remove the door handle cup screws.
3. Remove the door handle cup.
Low Series Door Trim Panels
4. Remove the screw and the window regulator handle.
All Door Trim Panels
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair > Page 9692
5. Remove the rear door trim panel.
1. Remove the screw. 2. Remove the rear door trim panel.
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair
Rear Door Window Glass: Service and Repair
Heavy Duty Riverter
SPECIAL TOOL(S)
REMOVAL
1. Remove the rear door trim panel.
2. Remove the interior glass weatherstrip.
3. Remove the rear door belt line moulding nut.
4. Remove the rear door belt line moulding.
CAUTION: Do not strike or force the front door belt line moulding during the installation. The front
door belt line moulding is made of aluminum and will be damaged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Page 9696
NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge
of the sheet metal and the door panel shelf.
5. Remove the rear door window glass rivets.
6. Remove the rear door window glass through the outboard side of the rear door.
INSTALLATION
1. To install, reverse the removal procedure.
^ Use the special tool to install the rivets.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Diagrams > Left
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Diagrams > Left > Page 9701
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Diagrams > Left > Page 9702
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Diagrams > Page 9703
Rear Door Window Motor: Service Precautions
CAUTION: Use care not to damage the drum housing when removing the rear window glass motor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Service and Repair > Rear Door Window Regulator Motor
Rear Door Window Motor: Service and Repair Rear Door Window Regulator Motor
REMOVAL
1. Remove the rear door window regulator.
2. Remove the rear door window regulator motor.
1 Remove the bolts.
2 Remove the rear door window regulator motor.
INSTALLATION
1. To install, reverse the removal procedure.
^ Cycle the door glass to make sure of engagement of the drive mechanism.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 9706
Rear Door Window Motor: Service and Repair Rear Window Glass Motor
REMOVAL
1. Remove the C-pillar trim panel. 2. Position the rear of the carpet aside. 3. Remove the water
shield from over the rear window glass motor and discard.
4. Remove the rear window motor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the rear window glass motor.
CAUTION: Use care not to damage the drum housing when removing the rear window glass motor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The rear window motor must be initialized after a repair is carried out.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 9707
Rear Door Window Motor: Service and Repair Rear Window Motor Initialization
1. Start with the ignition key in the OFF position. 2. Turn the ignition key to the ON position. 3.
Press the rear window glass control switch vent button six times. 4. Turn the ignition key to the
OFF position. 5. Press the rear window glass control switch vent button six more times. 6. Turn the
ignition key to the ON position. At this point the rear window glass will move up and down
approximately 20 mm (0.8 in). This
movement signifies that the rear window glass motor has entered into the initialization mode.
7. Hold the rear window glass control switch in the full up position until the rear window glass stops
in the full up position.
NOTE: The rear window glass control switch must be held in the up or down position until the
window glass stops moving. Failure to hold the switch will end the initialization operation. Then
initialization will have to be re-started.
8. Hold the rear window glass control switch in the full down position until the rear window glass
stops in the full down position.
NOTE: If a repair is to be carried out on the rear window glass release the rear window glass
control switch when it reaches the desired position. This will end the initialization operation.
9. Hold the rear window glass control switch in the full, up position until the rear window glass stops
in the full up position. At this time the window
will move up and down approximately 20 mm (0.8 in) signifying the rear window glass motor is
initialized.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair
Rear Door Window Regulator: Service and Repair
Heavy Duty Riverter
SPECIAL TOOL(S)
REMOVAL
1. Raise and support the rear door window glass to the full up position. 2. Remove the interior door
handle.
3. Remove the rear door speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
4. Remove the water shield.
5. Disconnect the rear door window regulator motor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair > Page 9711
6. Remove the rear door window regulator rivets.
7. Remove the rear door window regulator.
^ Slide the regulator arms off of the window glass track.
INSTALLATION
1. To install, reverse the removal procedure.
^ Use the special tool to install the rivets.
^ Cycle the door glass to make sure of engagement of the drive mechanism.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair > Page 9712
Heavy Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Technical Service Bulletins > Recalls for Hood Latch: > NHTSA00V394000 > Nov > 00 > Recall 00V394000: Hood Striker
Fracture/Failure
Hood Latch: Recalls Recall 00V394000: Hood Striker Fracture/Failure
Sport utility vehicles with steel hoods and certain pickup trucks equipped with sheet molding
compound hoods. A wire formed hood striker could be susceptible to fatigue fractures. If the hood
striker fractures, the hood could fly open while the vehicle is being driven.
A hood fly-up while the vehicle is being operated could result in reduced driver visibility.
Dealers will replace the hood striker. Owner notification is expected to begin during December
2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and
do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673.
Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at
1-888-DASH-2-DOT (1-888-327-4236).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Hood Latch: > NHTSA00V394000 > Nov > 00 > Recall
00V394000: Hood Striker Fracture/Failure
Hood Latch: All Technical Service Bulletins Recall 00V394000: Hood Striker Fracture/Failure
Sport utility vehicles with steel hoods and certain pickup trucks equipped with sheet molding
compound hoods. A wire formed hood striker could be susceptible to fatigue fractures. If the hood
striker fractures, the hood could fly open while the vehicle is being driven.
A hood fly-up while the vehicle is being operated could result in reduced driver visibility.
Dealers will replace the hood striker. Owner notification is expected to begin during December
2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and
do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673.
Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at
1-888-DASH-2-DOT (1-888-327-4236).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Technical Service Bulletins > Page 9727
Hood Latch: Service and Repair
REMOVAL
1. Remove the radiator grille sight shield.
1 Remove the bolts.
2 Release the retaining clips.
3 Remove the radiator grille sight shield.
2. Remove the bolts and position the hood latch aside.
3. Remove the hood latch.
1 Release the cable conduit.
2 Release the hood latch cable.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Technical Service Bulletins > Page 9728
1. Install the hood latch cable.
1 Install the hood latch cable.
2 Install the cable conduit.
2. Position the hood latch and install the bolts.
3. Align the hood latch.
1 loosen the hood latch bolts enough to allow for movement of the hood latch.
2 Align the hood latch with the hood latch striker.
4. Tighten the hood latch bolts. 5. Verify the hood latch striker is fully engaging the hood latch.
- If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford
specification ESR-M1C159-A to lubricate the latch.
- Repeat the install procedure as necessary to make sure the hood latch is aligned correctly.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Technical Service Bulletins > Page 9729
6. Install the radiator grille sight shield.
1 Position the sight shield.
2 Lock the clips.
3 Install the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component
Information > Service and Repair
Hood Latch Release: Service and Repair
REMOVAL
1. Remove the hood latch.
2. Remove the hood latch release handle screws.
3. Release the hood latch release cable.
1 Disconnect the cable conduit.
2 Release the cable.
4. Remove the two hood latch release handle cable locators. 5. Pull the hood latch release handle
cable towards the engine compartment and remove the cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 9738
OASIS CODES: 201000, 201200
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass >
Component Information > Service and Repair
Liftgate Window Glass: Service and Repair
REMOVAL
1. Open the liftgate glass.
2. Remove the two heated rear window electrical connector covers.
3. Disconnect the two heated rear window electrical connectors.
4. Remove the two liftgate lifting cylinder pins.
NOTE: An assistant may be needed to carry out this step.
5. Remove the liftgate window glass.
1 Position the liftgate trim panel aside.
2 Remove the access the covers and the liftgate window hinge nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass >
Component Information > Service and Repair > Page 9743
NOTE: An assistant may be needed to carry out this step.
6. Remove the liftgate window glass.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair
Trunk / Liftgate Handle: Service and Repair
SPECIAL TOOL(S)
Heavy Duty Riveter
REMOVAL
1. Remove the liftgate trim panel.
2. Remove the air escape vent panel.
1 Remove the pin-type retainers.
2 Remove the air escape vent panel.
3. Position the watershield aside.
4. Disconnect the liftgate release handle actuating rod.
1 Open the clip.
2 Disconnect the liftgate release handle actuating rod.
5. Remove the license plate lamp shield.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair > Page 9750
1 Remove the screws.
2 Remove the license plate lamp shield.
6. Remove the liftgate release handle.
1 Remove the rivets.
2 Remove the liftgate release handle.
INSTALLATION
1. To install, reverse the removal procedure.
- Using the special tool, install the rivets.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair > Page 9751
Heavy - Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim
Panel > Component Information > Service and Repair
Trunk / Liftgate Interior Trim Panel: Service and Repair
LIFTGATE TRIM PANEL
Removal and Installation
1. Open the liftgate glass.
2. Remove the liftgate handle.
1. Remove the liftgate handle screws. 2. Remove the liftgate handle.
3. Remove the liftgate trim panel screw access plug.
4. Remove the liftgate trim panel screw.
5. Remove the liftgate trim panel.
1. Remove the liftgate trim panel from the liftgate window opening. 2. Push the liftgate trim panel
toward the top of the liftgate and remove the liftgate trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim
Panel > Component Information > Service and Repair > Page 9755
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch
Trunk / Liftgate Latch: Service and Repair Liftgate Latch
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the liftgate trim panel.
3. Remove the air escape vent panel.
1 Remove the pin-type retainers.
2 Remove the air escape vent panel.
4. Remove the watershield.
5. Disconnect the liftgate latch release rod from the liftgate latch remote control.
1 Open the clip.
2 Disconnect the liftgate latch release rod.
6. Remove the liftgate latch.
1 Remove the bolts.
2 Disconnect the electrical connector.
3 Remove the liftgate latch and the liftgate release rod.
INSTALLATION
1. To install, reverse the removal procedure.
- If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford
specification ESR-M1C159-A to lubricate the latches.
NOTE: If installation of a new liftgate latch release rod is necessary, be sure to match the color coded rods
for correct installation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 9760
- Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a
relaxed state with no slack.
- Position the liftgate latch release rod by pushing outboard to remove the slack.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 9761
Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control
REMOVAL
1. Remove the liftgate latch actuator. 2. Remove the liftgate latch remote control from the liftgate.
- Transfer parts as necessary.
3. To install, reverse the removal procedure.
NOTE: Make sure the liftgate handle actuating rod is not preloading the liftgate latch remote
control. It should be clipped in a relaxed state with no slack.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 9762
Trunk / Liftgate Latch: Service and Repair Liftgate window Latch
REMOVAL
1. Disconnect the battery ground cable. 2. Open the liftgate window glass. 3. Remove the liftgate
trim panel.
4. Remove the air escape vent panel.
1 Remove the pin-type retainers.
2 Remove the air escape vent panel.
5. Remove the watershield.
6. Disconnect the liftgate window latch actuating rod.
1 Open the clip.
2 Disconnect the liftgate window latch actuating rod.
7. Disconnect the liftgate window ajar switch electrical connector and remove the nuts.
NOTE: Mark the position of the liftgate window latch prior to removing the nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 9763
8. Remove the liftgate window latch.
INSTALLATION
1. Position the liftgate window latch and loosely install the nuts. 2. Move the liftgate window glass to
the closed position.
3. Adjust the liftgate window latch.
- Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush.
4. Tighten the liftgate window latch nuts.
- If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford
specification ESR-M1C159-A to lubricate the latches.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 9764
5. Connect the liftgate window latch actuating rod.
1 Connect the liftgate window latch actuating rod.
2 Lock the clip.
6. Verify the liftgate window glass adjustment.
INSTALLATION
1. Install the watershield.
2. Install the air escape vent panel.
1 Position the air escape vent panel.
2 Install the pin-type retainers.
2. Install, the liftgate trim panel. 3. Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Service and Repair
Trunk / Liftgate Lock Cylinder: Service and Repair
REMOVAL
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. Remove the liftgate latch remote control.
2. Remove the liftgate lock cylinder.
1 Remove the nuts.
2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Service and Repair
Trunk / Liftgate Solenoid: Service and Repair
REMOVAL
1. Remove the liftgate window latch.
2. Disconnect the liftgate latch release rods.
1 Open the clips.
2 Disconnect the liftgate latch release rods.
3. Disconnect the liftgate release handle actuating rod.
1 Open the clip.
2 Disconnect the liftgate release handle actuating rod.
4. Disconnect the lock cylinder actuating rod.
1 Open the clip.
2 Disconnect the lock cylinder actuating rod.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Service and Repair > Page 9771
5. Remove the liftgate lock remote control bolt.
6. Disconnect the liftgate lock actuator electrical connector.
7. Remove the liftgate lock actuator nuts. 8. Move the liftgate latch remote control to the LH
opening and remove the liftgate latch actuator.
INSTALLATION
1. Connect and position the liftgate latch actuator.
2. Install the liftgate latch actuator nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Service and Repair > Page 9772
3. Connect the liftgate latch actuator electrical connector. 4. Position the liftgate latch remote
control.
5. Loosely install the liftgate latch remote control bolt.
6. Position the liftgate window latch and loosely install the nuts and connect the electrical
connector. 7. Move the liftgate window glass to the closed position.
8. Adjust the liftgate window latch.
- Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Service and Repair > Page 9773
9. Tighten the liftgate window latch nuts.
- If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford
specification ESR-M1C159-A to lubricate the latches.
10. Connect the liftgate window latch actuating rod.
1 Connect the liftgate window latch actuating rod.
2 Lock the clip.
11. Verify the liftgate window glass adjustment.
12. Tighten the liftgate latch remote control bolt.
13. Connect the lock cylinder actuating rod.
1 Position the lock cylinder actuating rod.
2 Close the clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Service and Repair > Page 9774
NOTE: Be sure the bell crank of the liftgate latch remote control is in the unlocked position
(upward) for correct lock cylinder rod length.
14. Connect the liftgate release handle actuating rod.
1 Position the liftgate release handle actuating rod.
2 Close the clip.
NOTE: Make sure the liftgate release handle actuating rod is not preloading the liftgate latch
remote control. It should be clipped in a relaxed state with no slack.
15. Connect the liftgate latch release rods.
1 Position the liftgate latch release rods by pushing outboard to remove the slack.
2 Close the clips.
NOTE: Make sure the latch release rods are not preloading the liftgate latch. They should be
clipped in a relaxed state with no slack.
16. Install the watershield.
17. Install the air escape vent panel.
1 Position the air escape vent panel.
2 Install the pin-type retainers.
18. Install the liftgate trim panel. 19. Connect the battery ground cable.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Ajar Switch
Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Ajar Switch > Page 9779
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 9780
Trunk / Liftgate Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 9781
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Service and Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Disconnect the driver side windshield washer hose from inside the engine compartment.
2. Remove the windshield wiper pivot arms.
1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull
the windshield wiper pivot arm from the windshield wiper pivot shaft.
3. Remove the cowl grille screw.
4. Remove the driver side cowl grille.
- Pull up on the cowl grille to disengage the clips.
5. Remove the passenger side cowl grille.
- Pull up on the cowl grille to disengage the clips and disconnect the washer hose.
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair
Front Fender Liner: Service and Repair
FENDER SPLASH SHIELD
Removal and Installation
Both Sides
1. Remove the fender splash shield front bolts.
2. Remove the fender splash shield screws.
LH Side
3. From inside the engine compartment, disconnect the wiring harness retainers from the fender
splash shield.
4. Remove the ABS module nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Page 9791
RH Side
5. Position the vacuum reservoir aside.
1. Remove the bolts. 2. Position the vacuum reservoir aside.
6. Remove the fender splash shield bolts.
Both Sides
7. Remove the fender splash shield. 8. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation
Body / Frame Mount Bushing: Description and Operation
FRAME AND BODY MOUNTING
Explorer Sport/Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9796
Explorer Sport/Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9797
Explorer Sport/Sport Trac
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9798
Explorer Sport
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9799
Explorer Sport
The frame consists of two steel channel rails, a rear crossmember, additional support
crossmembers and a front crossmember.
The rails and crossmembers are not to be removed from the frame to be repaired.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair
Grille: Service and Repair
RADIATOR GRILLE
Removal and Installation
1. Remove the front bumper cover.
2. Remove the radiator grilles.
1. Remove the four pin-type retainers. 2. Release the six clips. 3. Remove the radiator grilles.
3. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications
Console: Specifications
Torque Specifications, Part 1
Torque Specifications, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications
> Page 9807
Console: Description and Operation
Overhead Console
The overhead console consists of the following components: compass/thermometer display
- garage door opener storage (without roof opening panel)
- map/courtesy lamps
- map/courtesy lamp switch
- roof opening panel control switch (with roof opening panel)
Floor Console
The high series floor console consists of the following components: armrest
- ashcup
- bin mat
- console finish panel
- coin holder
- power point
- cup holder insert
- storage compartment
- rear cup holders
- rear integrated control panel
The base floor console consists of the following components: arm rest
- carry bag
- front cup holders
- rear cup holders
If the vehicle is equipped with manual transmission, there will be a consolette at the base of the
gearshift lever. The consolette contains two cupholders, covers the Restraint Control Module
(RCM) and is attached by two screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console - Base Series
Console: Service and Repair Floor Console - Base Series
REMOVAL
1. Remove the front seat center armrest.
1 Remove the two covers.
2 Remove the four bolts.
3 Remove the armrest.
2. Remove the utility tray beverage holder.
3. Remove the floor console.
1 Remove the screws.
2 Remove the floor console.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console - Base Series > Page 9810
Console: Service and Repair Floor Console - High Series
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the floor console tray.
- Lift upward at the rear first.
3. Disconnect the floor console electrical connectors.
4. Remove the floor console front bolts.
5. Remove the floor console center bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console - Base Series > Page 9811
6. Remove the floor console.
NOTE: The console must be moved rearward to disengage the rear mounting bracket.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console - Base Series > Page 9812
Console: Service and Repair Overhead Console
REMOVAL
1. Disconnect the battery ground cable.
2. If equipped, open the garage door remote cover.
3. If equipped, remove the screws.
4. Remove the overhead console.
NOTE: On vehicles equipped with a roof opening panel the overhead console is a snap-fit.
5. Disconnect the electrical connector (two connectors on vehicles equipped with a roof opening
panel).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console - Base Series > Page 9813
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Seats Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Disconnect the battery ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical
connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air
bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor
connector.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side floor connector. 11. Reconnect the battery ground cable.
Seats Not Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery
ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9819
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate
controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint
system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector
to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector
beneath the front seat.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
passenger side air bag electrical connector beneath
the front seat.
11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat.
12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side air bag electrical connector beneath the
front seat.
13. Reconnect the battery ground cable.
Deactivation Procedure
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will This will
reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9820
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood connected.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9821
8. Remove the driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
11. Open the glove compartment door past its stops to access the mounting screws.
12. Remove the two screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9822
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door. Reaching one hand into the glove
compartment opening push out on the passenger air bag module and separate it from the
instrument panel. Note the wire harness routing for installation.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
Vehicles without seat side air bags
16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag
bridge resistor from the side air bag to floor connector.
If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints
control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor
connector, a low resistance fault will be generated by the RCM.
Vehicles with seat side air bags and power driver seat
17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the battery ground
cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Vehicles with seat side air bags
18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side
air bags and power driver seat
19. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery
ground cable (14301) and wait at least one minute. For additional information, See: Starting and
Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9823
Vehicles with seat side air bags
20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
All vehicles
24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close
the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery
Reactivation Procedure
Reactivation
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9824
1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the
instrument panel, open the kick panel cover and remove the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the wiring Diagram Manual.
3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
Vehicles with seat side air bags
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
Vehicles with seat side air bags and power driver seat
8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9825
Vehicles with seat side air bags
9. Position the front seats rearward.
Vehicles with seat side air bags and power driver seat
10. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air
bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply
energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery
All vehicles
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical
connector.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Position the passenger air bag module into the instrument panel. Route the wire harness as noted
in removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9826
14. Install the two screws.
15. Close the glove compartment door.
16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
17. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to
the steering wheel.
18. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9827
19. Install the two steering wheel back cover plugs.
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear
blower, 15A with rear blower) to the CJB and close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to
OFF. Wait 10 seconds, then turn the key back to
ON and visually monitor the air bag indicator with the air bag modules installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an air bag
supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light.
-remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after
the ignition switch has been turned from the OFF to the ON position. This is the time required for
the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is
inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this
occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
25. Clear all continuous DTCs from the restraints control module using a scan tool.
Procedures For Repair Operations
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9828
accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9829
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9830
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9831
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9832
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Seats Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic
tool from the driver seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger
seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic
tool from the clockspring connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9833
8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable.
10. Prove out the system.
Seats Not Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring
connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove
the restraint system diagnostic tool from the floor connector beneath the front passenger seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the
passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from
the floor connector beneath the driver seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver
seat.
10. Reconnect the battery ground cable. 11. Prove out the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9834
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9835
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint
System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Procedures
Headliner: Procedures
REMOVAL
All Vehicles
1. Disconnect the battery ground cable.
Sport Trac
2. Remove the C-pillar trim panel.
Explorer Sport
3. Remove the rear quarter trim panel.
All Vehicles
4. Remove the overhead console.
5. Remove the interior lamp lens.
6. Remove the screws and the interior lamp.
7. Remove the two sun visors.
1 Remove the six screws.
2 Remove the two sun visors. If equipped, disconnect the electrical connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Procedures > Page 9840
8. Remove the two sun visor brackets.
1 Remove the two screws.
2 Remove the two sun visor brackets.
9. Remove the six assist handle bolt covers.
10. Remove the three assist handles.
1 Remove the six bolts.
2 Remove the three assist handles.
Sport Trac
11. Remove the passenger seat.
NOTE: The headliner is removed through the passenger side front door.
All Vehicles
12. Remove the headliner.
INSTALLATION
1. To install, reverse the removal procedure
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Procedures > Page 9841
Headliner: Removal and Replacement
HEADLINER
Removal and Installation
All Vehicles
1. Disconnect the battery ground cable.
Sport Trac
2. Remove the C-pillar trim panel.
Explorer Sport
3. Remove the rear quarter trim panel.
All Vehicles
4. Remove the overhead console.
5. Remove the interior lamp lens.
6. Remove the screws and the interior lamp.
7. Remove the two sun visors.
1. Remove the six screws. 2. Remove the two sun visors. If equipped, disconnect the electrical connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Procedures > Page 9842
8. Remove the two sun visor brackets.
1. Remove the two screws. 2. Remove the two sun visor brackets.
9. Remove the six assist handle bolt covers.
10. Remove the three assist handles.
1. Remove the six bolts. 2. Remove the three assist handles.
Sport Trac
11. NOTE: The headliner is removed through the passenger side front door.
Remove the passenger seat.
All Vehicles
12. Remove the headliner. 13. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures
Trim Panel: Procedures
B-Pillar Trim Panel
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
1. Remove the windshield side garnish moulding.
2. Remove the scuff plate.
1 Starting at one end and working along the scuff plate, release the scuff plate locking tabs.
2 Remove the scuff plate.
3. Remove the coat hook.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9847
1 Remove the screw.
2 Remove the coat hook.
4. Open the front safety belt guide bolt cover.
5. Using the special tool, remove the front safety belt guide bolt. 6. Position the carpet aside.
7. Using the special tool, remove the front safety belt anchor bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9848
8. Remove the B-pillar trim panel.
1 Remove the pin-type retainer.
2 Feed the safety belt webbing through the opening.
3 Remove the B-pillar trim panel.
INSTALLATION
1. To install, reverse the removal procedure.
C-Pillar Trim Panel
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
1. Remove the B-pillar trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9849
2. Open the rear safety belt guide bolt cover.
3. Using the special tool, remove the rear safety belt guide bolt. 4. Position the carpet aside.
5. Remove the rear safety belt anchor nut.
6. Remove the roof trim panel.
7. Remove the six luggage compartment back lower trim cover screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9850
8. Remove the luggage compartment back lower trim cover.
- Remove the six pin-type retainers.
9. Remove the pin-type retainer from C-pillar trim panel.
10. Remove the safety belt anchor trim cover.
11. Remove the C-pillar trim panel.
- Feed the safety belt webbing through the opening.
INSTALLATION
1. To install, reverse the removal procedure.
Liftgate Trim Panel
REMOVAL
1. Open the liftgate glass.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9851
2. Remove the liftgate handle.
1 Remove the liftgate handle screws.
2 Remove the liftgate handle.
3. Remove the liftgate trim panel screw access plug.
4. Remove the liftgate trim panel screw.
5. Remove the liftgate trim panel.
1 Remove the liftgate trim panel from the liftgate window opening.
2 Push the liftgate trim panel toward the top of the liftgate and remove the liftgate trim panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9852
Rear Quarter Trim Panel
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
1. Remove the windshield side garnish moulding.
2. Remove the scuff plate.
3. Remove the front safety belt guide bolt cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9853
4. Using the special tool, remove the front safety belt guide bolt. 5. Position the carpet aside.
6. Using the special tool, remove the front safety belt anchor bolt.
7. If equipped, remove the retractable cargo cover. 8. Remove the liftgate scuff plate. 9. Fold the
rear seat into the load floor position.
10. Using the special tool, remove the rear safety belt guide bolt. 11. Position the carpet aside.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9854
12. Using the special tool, remove the rear safety belt anchor bolt.
13. Remove the rear quarter window latch screws.
14. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
15. Remove the quarter trim panel front screw.
- Position the carpet aside to gain access to the screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9855
16. Remove the three quarter trim panel rear screws.
- Position the carpet aside to gain access to the screws.
17. If equipped, remove the rear door lock control switch assembly.
- Disconnect the electrical connector.
18. Remove the quarter trim panel.
1 Remove the eight pin-type retainers.
2 Feed the safety belt webbing through the opening in the quarter trim panel.
3 Remove the quarter trim panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9856
Trim Panel: Removal and Replacement
C-Pillar Trim Panel
C-PILLAR TRIM PANEL
Special Tool(s)
Special Tool(s)
Removal and Installation
1. Remove the B-pillar trim panel.
2. Open the rear safety belt guide bolt cover.
3. Using the special tool, remove the rear safety belt guide bolt. 4. Position the carpet aside.
5. Remove the rear safety belt anchor nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9857
6. Remove the roof trim panel.
7. Remove the six luggage compartment back lower trim cover screws.
8. Remove the luggage compartment back lower trim cover.
- Remove the six pin-type retainers.
9. Remove the pin-type retainer from C-pillar trim panel.
10. Remove the safety belt anchor trim cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9858
11. Remove the C-pillar trim panel.
- Feed the safety belt webbing through the opening.
12. To install, reverse the removal procedure.
Rear Quarter Trim Panel
REAR QUARTER TRIM PANEL
Special Tool(s)
Special Tool(s)
Removal and Installation
1. Remove the windshield side garnish moulding.
2. Remove the scuff plate.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9859
3. Remove the front safety belt guide bolt cover.
4. Using the special tool, remove the front safety belt guide bolt. 5. Position the carpet aside.
6. Using the special tool, remove the front safety belt anchor bolt.
7. If equipped, remove the retractable cargo cover. 8. Remove the liftgate scuff plate. 9. Fold the
rear seat into the load floor position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9860
10. Using the special tool, remove the rear safety belt guide bolt. 11. Position the carpet aside.
12. Using the special tool, remove the rear safety belt anchor bolt.
13. Remove the rear quarter window latch screws.
14. Remove the coat hook.
1. Remove the screw. 2. Remove the coat hook.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9861
15. Remove the quarter trim panel front screw.
- Position the carpet aside to gain access to the screw.
16. Remove the three quarter trim panel rear screws.
- Position the carpet aside to gain access to the screws.
17. If equipped, remove the rear door lock control switch assembly.
- Disconnect the electrical connector.
18. Remove the quarter trim panel.
1. Remove the eight pin-type retainers. 2. Feed the safety belt webbing through the opening in the
quarter trim panel. 3. Remove the quarter trim panel.
19. To install, reverse the removal procedure.
Trim Panel - B-Pillar
B-PILLAR TRIM PANEL
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9862
Special Tool(s)
Special Tool(s)
Removal and Installation
1. Remove the windshield side garnish moulding.
2. Remove the scuff plate.
1. Starting at one end and working along the scuff plate, release the scuff plate locking tabs. 2.
Remove the scuff plate.
3. Remove the coat hook.
1. Remove the screw. 2. Remove the coat hook.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9863
4. Open the front safety belt guide bolt cover.
5. Using the special tool, remove the front safety belt guide bolt. 6. Position the carpet aside.
7. Using the special tool, remove the front safety belt anchor bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Procedures > Page 9864
8. Remove the B-pillar trim panel.
1. Remove the pin-type retainer. 2. Feed the safety belt webbing through the opening. 3. Remove
the B-pillar trim panel.
9. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair
Door Lock Cylinder: Service and Repair
REMOVAL
NOTE:
- When a new lock cylinder is installed, both door lock cylinders, liftgate lock cylinders, tailgate and
ignition lock cylinder should be installed as a set. This will eliminate carrying an extra key which will
fit only one lock. If a new key is to be used, the new key code number is stamped on a metal tag
attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. Remove the front door trim panel. 2. Make sure the window is in the fully raised position. 3.
Position the watershield aside.
4. Remove the door lock cylinder.
1 Disconnect the lock cylinder rod.
2 Remove the retaining clip.
3 Remove the door lock cylinder.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics
Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics
TSB 06-15-8
08/07/06
KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY
FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005
Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006
Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006
F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005
Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar
LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator
2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT
MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan
1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner
ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to
properly diagnose the concern with the keyless entry keypad, it is important to identify whether the
keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF)
style keypad.
ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic
service tips.
SERVICE PROCEDURE
IDENTIFICATION:
1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and
are wired directly to the module controlling the vehicle's keyless entry system. This style keypad
can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9875
2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13
mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM
(Figure 1).
NOTE
THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES
BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD
DIAGNOSTICS FOR THESE VEHICLES.
GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS
1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed
using a similar procedure.
Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter
programming portion of the WSM, Section 501-14 can be used as a guide
NOTE
THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY
DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN
ADDITIONAL REMOTE TRANSMITTER.
Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic
pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the
lock / unlock functions will differ
2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced
separately.
3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be
replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super
Duty vehicles produced prior to 12/3/2003).
4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by
vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is
replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM
etc.) is replaced.
NOTE
THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED
KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR
VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN
THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME
ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING
PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD
SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL
CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE.
5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the
illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all
doors). The keypad contains an optical sensor and will not illuminate under bright lighting
conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the
battery power available to transmit a lock/unlock signal. The temperature at which this occurs will
vary depending upon the keypad battery age and condition. Both of these conditions are a normal
function of the Power Save Mode and do not indicate a need to replace the keypad.
6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it
again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication
that battery power is very low and the keypad must be replaced.
7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35
consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash
during this time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9876
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A626 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 9877
Keyless Entry Key-Pad: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 9878
Keyless Entry Key-Pad: Service and Repair
REMOVAL
1. Remove the front door speaker.
2. Disconnect the keyless entry electrical connector.
3. Remove the two wiring harness locators.
4. Release the retaining clip.
5. Remove the key less entry keypad.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Locations
Keyless Entry Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9884
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9885
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9886
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9887
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9888
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9889
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9890
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9891
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9892
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9893
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9894
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9895
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9896
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9897
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9898
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9899
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9900
Keyless Entry Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9901
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9902
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9903
Keyless Entry Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 9904
Keyless Entry Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Page 9905
Keyless Entry Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Driver Side > Page 9911
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Driver Side > Page 9912
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Driver Side > Page 9913
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Page 9914
Power Door Lock Actuator: Service and Repair
Heavy Duty Riveter
SPECIAL TOOL(S)
REMOVAL
1. Remove the front door trim panel. 2. Position the watershield aside.
3. Remove the door glass run channel.
1 Remove the bolt.
2 Remove the door glass run channel. Release the wiring harness locator.
4. Disconnect the door lock actuator electrical connector.
5. Remove the front door lock actuator rivet.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Page 9915
6. Release the wiring harness locator. 7. Remove the front door lock actuator.
INSTALLATION
1. To install, reverse the removal procedure.
- Using the special tool, install the rivet.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Page 9916
Heavy - Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Locations
Power Door Lock Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions
Power Door Lock Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9922
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9923
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9924
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9925
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9926
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9927
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9928
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9929
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9930
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9931
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9932
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9933
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9934
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9935
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9936
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9937
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9938
Power Door Lock Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9939
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9940
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9941
Power Door Lock Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 9942
Power Door Lock Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Page 9943
Power Door Lock Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Locations > Driver Door Unlock Relay
Power Door Lock Relay: Locations Driver Door Unlock Relay
Diagram 700-01-00-6
Diagram 700-01-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Locations > Driver Door Unlock Relay > Page 9948
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Diagrams > Driver Door Unlock Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Diagrams > Driver Door Unlock Relay > Page 9951
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Diagrams > Driver Door Unlock Relay > Page 9952
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Diagrams > Page 9953
Power Door Lock Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Diagrams > Page 9954
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Driver Side > Page 9959
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Door Lock Switch, Driver Side
Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Door Lock Switch, Driver Side > Page 9962
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Door Lock Switch, Driver Side > Page 9963
Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Door Lock Switch, Driver Side > Page 9964
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service
and Repair
Trunk / Liftgate Lock Cylinder: Service and Repair
REMOVAL
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. Remove the liftgate latch remote control.
2. Remove the liftgate lock cylinder.
1 Remove the nuts.
2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page
9972
Power Mirror Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page
9973
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Premature Clearcoat Cracking Service Tips
Paint: Technical Service Bulletins Paint - Premature Clearcoat Cracking Service Tips
Article No. 02-17-1
PAINT-PREMATURE CLEARCOAT CRACKING-SERVICE TIPS
FORD: 1999-2002 EXPLORER
2000-2002 EXPLORER SPORT TRAC, EXPLORER SPORT
MERCURY: 1999-2002 MOUNTAINEER
ISSUE
Some vehicles may exhibit crowsfoot or premature star cracking primarily on the hood, but could
also be on other panels. This is due to high paint film build and acrylic melamine paint technology.
ACTION
Read this TSB in its entirety BEFORE beginning any repairs. Inspect and repair as outlined in
following Service Procedures.
SERVICE PROCEDURE
1999-2002 Vehicles-Dark Colors (Code LL Blue, Code UA Black, and Code SU Green only)
NOTE READ THIS REPAIR PROCEDURE COMPLETELY. SUBJECT VEHICLES HAVE PAINT
THICKNESS ABOVE 5.5 MILS.
1. Check paint film thickness on affected panels.
NOTE IF PLASTIC MEDIA BLASTING IS BEING USED, PROCEED TO STEP 4.
NOTE TECHNICIAN PERFORMING THE SANDING OPERATION SHOULD WEAR AN
APPROVED RESPIRATOR WITH HIGH EFFICIENCY PARTICULATE FILTERS (HEPA).
TECHNICIANS SHOULD USE A DUAL ACTION SANDER WITH VACUUM COLLECTION
EQUIPMENT. THE VACUUM EQUIPMENT MUST BE EQUIPPED WITH A HEPA FILTER ON
THE AIR EXHAUST. OPERATORS ARE CAUTIONED TO FOLLOW MANUFACTURERS
GUIDELINES FOR MAINTENANCE OR REPLACEMENT OF THESE FILTERS.
2. Remove all clearcoat and basecoat by sanding down to the E-coat primer with 80 grit-sanding
discs on a Dual Action vacuum sander. The E-coat
color is Green.
3. Blow off the panel with compressed air to remove loose dust and debris. 4. Wipe the panel with
a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. Keep
wiping until the surface is
completely dry.
5. Mask off all necessary panels. Tack off the surface. 6. Mix and apply Ford Approved epoxy or
self-etching primer to all bare metal areas on the panel. 7. Mix and apply 2.0 mils minimum of Ford
Approved primer surfacer following the manufacturers label recommendations and bake at 140°F
(60°
C) panel temperature per manufacturers recommended baking time.
8. Block sand the affected panels with 600 grit sand paper. 9. Blow off the area with compressed
air to remove loose dust and debris.
10. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to
remove all residue.
NOTE KEEP WIPING UNTIL THE SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY
RESULT CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP.
11. Mix and apply Ford Approved basecoat material following the manufacturers label
recommendations and flash time. 12. Mix and apply 2.0 mils minimum of Ford Approved clearcoat
and bake at 140°F (60°C) panel temperature per manufacturers recommended
baking time.
13. Demask the vehicle as necessary.
WARNING TO SAFEGUARD OUR ENVIRONMENT, PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (VOC) OR EXCESS MATERIALS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Premature Clearcoat Cracking Service Tips > Page 9979
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 106000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes
Paint: Application and ID Paint Codes
Vehicle Certification (VC) Label, Part 1
Vehicle Certification (VC) Label, Part 2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9982
The Vehicle Certification (VC) label contains information on the manufacturer name, the month and
year of manufacture, the certification statement, and the VIN. It also includes the Gross Vehicle
Weight Rating (GVWR).
VEHICLE CERTIFICATION LABEL REFERENCE
Paint Codes
The first set of code numbers list the primary body color, the second set of code numbers list the
lower body or two-tone paint code (if applicable).
The following lists the exterior paint codes:
Primary body color codes B2 - Harvest Gold
- FY - Woodland Green (clear coat)
- FL - Medium Toreador Red
- LL - Deep Wedgewood Blue
- UA - Ebony
- YZ - Oxford White
- R1 - Island Blue (clear coat)
- RS - Silver Frost (clear coat)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9983
Tape/Paint Stripe Code
Tape or paint stripe codes do not apply.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9984
Paint: Application and ID Paint Code Sticker Location
VEHICLE CERTIFICATION LABEL REFERENCE
The VC label is located on the left-hand front door or door jamb and is in a similar location on
trucks.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Keyless Entry Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9991
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9992
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9993
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9994
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9995
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9996
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9997
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9998
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9999
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10000
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10001
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10002
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10003
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10004
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10005
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10006
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10007
Keyless Entry Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10008
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10009
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10010
Keyless Entry Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10011
Keyless Entry Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 10012
Keyless Entry Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Locations
Power Door Lock Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Power Door Lock Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10018
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10019
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10020
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10021
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10022
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10023
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10024
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10025
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10026
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10027
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10028
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10029
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10030
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10031
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10032
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10033
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10034
Power Door Lock Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10035
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10036
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10037
Power Door Lock Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10038
Power Door Lock Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Page 10039
Power Door Lock Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Driver Door Unlock Relay
Power Door Lock Relay: Locations Driver Door Unlock Relay
Diagram 700-01-00-6
Diagram 700-01-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Driver Door Unlock Relay > Page 10044
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Driver Door Unlock Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Driver Door Unlock Relay > Page 10047
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Driver Door Unlock Relay > Page 10048
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Page 10049
Power Door Lock Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Diagrams > Page 10050
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 10054
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Service and Repair
Sunroof / Moonroof Motor: Service and Repair
REMOVAL
1. Close the roof opening panel. If necessary, refer to Manual Operation.
2. Position the overhead console aside.
3. Remove the roof opening panel motor.
1 Remove the bolts.
2 Remove the roof opening panel motor. Disconnect the electrical connector.
NOTE: Make sure that the roof opening panel motor is in the closed position.
INSTALLATION
1. Connect the roof opening panel motor electrical connector. 2. With the ignition switch on and the
roof opening panel motor still removed, bump the roof opening panel switch one time only towards
the close
or vent position.
3. Install the roof opening panel motor.
1 Position the roof opening panel motor.
2 Install the roof opening panel bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Service and Repair > Page 10060
4. Install the overhead console.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Diagrams > Page 10064
Sunroof / Moonroof Switch: Service and Repair
REMOVAL
1. Position the overhead console aside.
2. Remove the roof opening panel control switch.
1 Remove the screws.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair
Sunroof / Moonroof Track: Service and Repair
REMOVAL
1. Remove the headliner.
2. Disconnect the roof opening panel motor electrical connector.
3. Remove the roof opening panel frame.
1 Disconnect the four drain hoses.
2 Remove the 18 screws.
3 Remove the roof opening panel frame.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair
Sunroof / Moonroof Windguard: Service and Repair
REMOVAL
1. Open the roof opening panel to the fully retracted position.
2. Release the two air deflector arms.
3. Remove the air deflector.
1 Detach the two air deflector retainer clips from the U-frame.
2 Remove the air deflector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise
Sunroof / Moonroof Frame: Customer Interest Body - Moonroof Squeak or Rattle Noise
TSB 05-3-4
02/21/05
MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer
4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise
coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail
assembly. A new corner insert is now available to correct the condition (Figure 2).
ACTION The corner inserts are located in both front corners of the moonroof track and can be
accessed by cycling the moonroof glass to the full open position. The original corner insert design
had snap tabs that may break off during installation, creating a rattle condition. Replace both of the
original inserts and remove any broken tabs left in the track. Refer to the following Service
Procedure.
SERVICE PROCEDURE
1. Open the moonroof to the full open position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 10079
2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver
and inspect the snap tabs (Figures 1 and 2).
3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose
debris (Figure 3).
4. Install a new corner insert on both sides (Figure 4).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 10080
OPERATION DESCRIPTION TIME
050304A 2001-2003 Explorer Sport, 0.3Hr.
2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator:
Replace Both Of The Moonroof Corner Inserts
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502B36 01
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise
Sunroof / Moonroof Frame: All Technical Service Bulletins Body - Moonroof Squeak or Rattle Noise
TSB 05-3-4
02/21/05
MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer
4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise
coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail
assembly. A new corner insert is now available to correct the condition (Figure 2).
ACTION The corner inserts are located in both front corners of the moonroof track and can be
accessed by cycling the moonroof glass to the full open position. The original corner insert design
had snap tabs that may break off during installation, creating a rattle condition. Replace both of the
original inserts and remove any broken tabs left in the track. Refer to the following Service
Procedure.
SERVICE PROCEDURE
1. Open the moonroof to the full open position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 10086
2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver
and inspect the snap tabs (Figures 1 and 2).
3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose
debris (Figure 3).
4. Install a new corner insert on both sides (Figure 4).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 10087
OPERATION DESCRIPTION TIME
050304A 2001-2003 Explorer Sport, 0.3Hr.
2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator:
Replace Both Of The Moonroof Corner Inserts
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502B36 01
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations > Page 10091
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair
Sunroof / Moonroof Panel: Service and Repair
REMOVAL
1. Open the roof opening panel to the vent position.
2. Remove the four lifter arm bolts.
3. From outside the vehicle, remove the roof opening panel.
INSTALLATION
1. To install, reverse the removal procedure.
- Check for correct alignment of the roof opening panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams
Power Seat Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions
> Technician Safety Information
Power Seat Switch: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR
BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
- TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions
> Technician Safety Information > Page 10104
Power Seat Switch: Vehicle Damage Warnings
CAUTION:
- Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat
not secured in the vehicle may result in damaged components.
- To prevent damage to the side shield, the clips must be depressed in order to release the side
shield from the cushion pan.
- Use care when disconnecting the seat cushion side shield from the seat cushion frame so the
tabs on the seat cushion side shield are not damaged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Except Side Air Bags
Power Seat Switch: Testing and Inspection Except Side Air Bags
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Except Side Air Bags > Page 10107
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Except Side Air Bags > Page 10108
Power Seat Switch: Testing and Inspection With Side Air Bags
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Except Side Air Bags > Page 10109
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag
Power Seat Switch: Service and Repair With Side Air Bag
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR
BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10112
connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to
operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10113
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
8. Using the special tool, remove the safety belt buckle support bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10114
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10115
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10116
21. Disconnect the clockspring electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO
DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
26. Remove the lumbar support knob.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10117
27. Remove the rear side shield screw.
28. Release the side shield clips.
CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release
the side shield from the cushion pan.
29. Unhook the side shield from the seat latch.
30. Remove the side shield.
1 Disconnect the electrical connector.
2 Remove the side shield.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10118
31. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS OR THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10119
1. Install the 6-way power seat switch.
1 Install the 6-way power seat switch.
2 Install the screws.
2. Install the side shield.
1 Install the side shield.
2 Install the electrical connector.
3. Hook the side shield to the seat latch.
4. Install the side shield clips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10120
5. Install the rear side shield screw.
6. Install the lumbar support knob. 7. Position the driver seat into the vehicle. Install the four seat
track to floor bolts and hand-tighten them.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
8. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10121
9. Connect the driver seat side air bag and power seat (if equipped) electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
3 Tie-strap the wire harness.
10. Connect the battery ground cable. 11. Position the driver seat rearward. 12. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
13. Tighten the driver seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
14. Move and tilt the driver seat to its highest and most forward position.
15. Tighten the driver seat rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
16. Install the driver seat rear track bolt covers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10122
17. Connect the safety belt warning indicator electrical connector.
18. Using the special tool, install the safety belt buckle support bolt.
19. Install the safety belt buckle support bolt cover. 20. Position the driver seat rearward. 21.
Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO
DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
22. Position the passenger seat forward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10123
23. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
24. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 25.
Position the passenger seat rearward.
26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
27. Install the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10124
28. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
29. Connect the clockspring electrical connector at the base of the steering column.
30. Position the lower steering column opening finish panel reinforcement and install the bolts.
31. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10125
32. Position the hood release handle and install the screws. 33. Connect the battery ground cable.
34. With all the diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
35. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10126
Power Seat Switch: Service and Repair Without Side Air Bag
REMOVAL
1. Remove the front seat.
2. Remove the lumbar control knob, if equipped.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
5. Remove the front seat cushion side shield screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
With Side Air Bag > Page 10127
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Remove the front seat cushion side shield.
8. Remove the 6-way power seat switch.
- Remove the screws, then remove the 6-way power seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Page 10128
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > NHTSA06V114000 > Apr > 06 > Recall 06V114000: Seat Back Recliner
Bolt Defect
Seat Back Frame: Recalls Recall 06V114000: Seat Back Recliner Bolt Defect
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer Sport 2001-2002 MANUFACTURER:
Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V114000 MFG'S REPORT DATE: April
05, 2006
COMPONENT: Seats: Front Assembly: Recliner
POTENTIAL NUMBER OF UNITS AFFECTED: 8585
SUMMARY: On certain sport utility vehicles equipped with high back seats, the upper bolt on the
driver's side high back seat that attaches the seat recliner mechanism to the seat back frame,
could fracture. If the bolt fractures, the seat back may recline until it makes contact with an object
behind the seat, such as the second row seat cushion.
CONSEQUENCE: The driver could potentially lose contact with the steering wheel or foot pedals
during such an event, increasing the risk of a crash.
REMEDY: Dealers will replace the driver seat upper bolt with a metal spacer and bolt. In addition,
seats with tubular back frames will have the fully threaded lower recliner bolt replaced with a
partially threaded bolt. The recall is expected to begin on April 10, 2006. Owners may contact Ford
at 1-800-392-3673. This is a supplement to a previous recall campaign (NHTSA03V281000).
NOTES: Ford recall No. 03S04S1. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect
Technical Service Bulletin # 03S04S1 Date: 060401
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10142
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006.
FSA VIN LIST ACTIVATED? Yes
Available through the website by April 5, 2006.
Owner names and addresses will be available for the additional vehicles by April 17, 2006.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
Related damage claims are not approved for this program.
ADDITIONAL LABOR TIME
This repair will require no additional labor time to complete. Claims submitted with "MT" labor will
not be accepted for reimbursement.
OWNER REFUNDS
^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair
was performed prior to the date indicated in the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10143
reimbursement plan, which is posted with this bulletin. This plan is also available to owners through
the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement
through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box
6251, Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund
claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be
accepted for reimbursement.
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the vehicle.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 03S04 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refund or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires approval from Special Service Support
Center.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will
only be used on approximately 25% of the repairs.
The DOR/COR for this program is 50309. This number identifies parts ordered for this recall
through the Special Service Support Center.
RECALL PARTS SUPPORT CENTER
The Recall Parts Support Center can be contacted via:
^ Phone
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10144
^ E-mail
^ FAX
Please be prepared to provide the following information:
^ Dealer Name and P & A code
^ Contact Name
^ Phone number and E-mail address
^ FSA #: 03804
^ Vehicle Identification Number (if requested)
DEALER PRICE
For latest prices1 refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures".
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW
This procedure involves replacement of certain seat recliner assembly attaching hardware on two
different style driver seat assemblies. The driver seat will have either a stamped seat back frame or
a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the
seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2.
^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner
mechanism attaches to the seatback frame. See Figure 1.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10145
^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is
evident on the tubular seatback frame. See Figure 2.
For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure
3.
^ Stamped Seatback - The kit consists of:
- One (1) UPPER bolt with thread sealer patch (bolt A)
- One (1)1-inch spacer (spacer A)
^ Tubular Seatback - The kit consists of:
- One (1) UPPER bolt with thread sealer patch (bolt A)
- One (1) LOWER bolt without thread sealer patch (bolt B)
- One (1) 3/4-inch spacer (spacer B)
SERVICE PROCEDURE
FOR ALL AFFECTED VEHICLES
WARNING:
ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL
RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
WARNING:
TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER
DEVICES.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10146
If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is
being serviced, the supplemental restraint system (SRS) must be depowered.
1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim
and accessories may vary from one seat to another of the same frame configuration.
Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover
and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back
frame.
2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio
stations.
3. Position the driver seat to its full-forward position.
4. Turn the ignition switch from RUN to OFF.
5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge
area and then remove the applicable airbag fuse. Refer to the following chart to determine which
fuse must be removed when working on a vehicle with side air bags.
6. Disconnect the battery negative cable and wait one minute.
7. Position the driver seatback to Its full4orward position.
8. CAUTION: Take care not to damage the seatback trim cover during this step.
Unhook the seatback trim cover J-clip. See Figure 4.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10147
9. Position the driver seatback to a straight-up position. See Figure 5.
10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See
Figure 6.
11. Remove and discard the upper bolt.
12. Remove and discard the plastic bushing. See Figure 7.
13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3.
^ Spacer A 1-inch on STAMPED seatback frames.
^ Spacer B 3/4-Inch on TUBULAR seatback frames.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10148
Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer
should be between the recliner mechanism arm and the seatback frame. See Figure 8.
14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft).
15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original
position.
16. Position the driver seatback to its full4orward position.
17. Connect the seatback trim cover J-clip.
18. Position the driver seatback to its original position.
^ If the vehicle is equipped with a tubular seatback frame, go to Step 23.
^ If the vehicle is equipped with a stamped seatback frame, continue with the next step.
19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the
ignition switch from OFF to RUN.
20. Install the airbag fuse and then install the fuse box cover.
21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING
BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE
CABLE IS CONNECTED.
Connect the battery negative cable.
22. Position the driver seat to its original position and program the recorded preset radio stations.
THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK
FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS.
23. Position the seat cushion side shield aside as follows:
^ Pull off the lumbar support manual adjuster knob, if equipped.
^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment).
^ GENTLY unsnap the shield from the seat frame and position the shield out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10149
24. Remove and discard the lower bolt from the recliner assembly. See Figure 9.
25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft).
26. Install the seat cushion side shield as follows:
^ Align and snap the shield into place.
^ Install the two (2) removed screws.
^ Install the lumbar support adjuster knob.
27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the
ignition switch from OFF to RUN.
28. Install the airbag fuse and then install the fuse box cover.
29.
WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING
BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE
CABLE IS CONNECTED.
Connect the battery negative cable.
30. Position the driver seat to its original position and program the recorded preset radio stations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10150
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10151
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10152
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > NHTSA06V114000 > Apr > 06 > Recall
06V114000: Seat Back Recliner Bolt Defect
Seat Back Frame: All Technical Service Bulletins Recall 06V114000: Seat Back Recliner Bolt
Defect
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer Sport 2001-2002 MANUFACTURER:
Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V114000 MFG'S REPORT DATE: April
05, 2006
COMPONENT: Seats: Front Assembly: Recliner
POTENTIAL NUMBER OF UNITS AFFECTED: 8585
SUMMARY: On certain sport utility vehicles equipped with high back seats, the upper bolt on the
driver's side high back seat that attaches the seat recliner mechanism to the seat back frame,
could fracture. If the bolt fractures, the seat back may recline until it makes contact with an object
behind the seat, such as the second row seat cushion.
CONSEQUENCE: The driver could potentially lose contact with the steering wheel or foot pedals
during such an event, increasing the risk of a crash.
REMEDY: Dealers will replace the driver seat upper bolt with a metal spacer and bolt. In addition,
seats with tubular back frames will have the fully threaded lower recliner bolt replaced with a
partially threaded bolt. The recall is expected to begin on April 10, 2006. Owners may contact Ford
at 1-800-392-3673. This is a supplement to a previous recall campaign (NHTSA03V281000).
NOTES: Ford recall No. 03S04S1. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect
Technical Service Bulletin # 03S04S1 Date: 060401
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10162
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006.
FSA VIN LIST ACTIVATED? Yes
Available through the website by April 5, 2006.
Owner names and addresses will be available for the additional vehicles by April 17, 2006.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
Related damage claims are not approved for this program.
ADDITIONAL LABOR TIME
This repair will require no additional labor time to complete. Claims submitted with "MT" labor will
not be accepted for reimbursement.
OWNER REFUNDS
^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair
was performed prior to the date indicated in the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10163
reimbursement plan, which is posted with this bulletin. This plan is also available to owners through
the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement
through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box
6251, Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund
claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be
accepted for reimbursement.
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the vehicle.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 03S04 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refund or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires approval from Special Service Support
Center.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will
only be used on approximately 25% of the repairs.
The DOR/COR for this program is 50309. This number identifies parts ordered for this recall
through the Special Service Support Center.
RECALL PARTS SUPPORT CENTER
The Recall Parts Support Center can be contacted via:
^ Phone
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10164
^ E-mail
^ FAX
Please be prepared to provide the following information:
^ Dealer Name and P & A code
^ Contact Name
^ Phone number and E-mail address
^ FSA #: 03804
^ Vehicle Identification Number (if requested)
DEALER PRICE
For latest prices1 refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures".
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW
This procedure involves replacement of certain seat recliner assembly attaching hardware on two
different style driver seat assemblies. The driver seat will have either a stamped seat back frame or
a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the
seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2.
^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner
mechanism attaches to the seatback frame. See Figure 1.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10165
^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is
evident on the tubular seatback frame. See Figure 2.
For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure
3.
^ Stamped Seatback - The kit consists of:
- One (1) UPPER bolt with thread sealer patch (bolt A)
- One (1)1-inch spacer (spacer A)
^ Tubular Seatback - The kit consists of:
- One (1) UPPER bolt with thread sealer patch (bolt A)
- One (1) LOWER bolt without thread sealer patch (bolt B)
- One (1) 3/4-inch spacer (spacer B)
SERVICE PROCEDURE
FOR ALL AFFECTED VEHICLES
WARNING:
ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL
RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
WARNING:
TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER
DEVICES.
NOTE:
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10166
If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is
being serviced, the supplemental restraint system (SRS) must be depowered.
1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim
and accessories may vary from one seat to another of the same frame configuration.
Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover
and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back
frame.
2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio
stations.
3. Position the driver seat to its full-forward position.
4. Turn the ignition switch from RUN to OFF.
5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge
area and then remove the applicable airbag fuse. Refer to the following chart to determine which
fuse must be removed when working on a vehicle with side air bags.
6. Disconnect the battery negative cable and wait one minute.
7. Position the driver seatback to Its full4orward position.
8. CAUTION: Take care not to damage the seatback trim cover during this step.
Unhook the seatback trim cover J-clip. See Figure 4.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10167
9. Position the driver seatback to a straight-up position. See Figure 5.
10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See
Figure 6.
11. Remove and discard the upper bolt.
12. Remove and discard the plastic bushing. See Figure 7.
13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3.
^ Spacer A 1-inch on STAMPED seatback frames.
^ Spacer B 3/4-Inch on TUBULAR seatback frames.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10168
Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer
should be between the recliner mechanism arm and the seatback frame. See Figure 8.
14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft).
15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original
position.
16. Position the driver seatback to its full4orward position.
17. Connect the seatback trim cover J-clip.
18. Position the driver seatback to its original position.
^ If the vehicle is equipped with a tubular seatback frame, go to Step 23.
^ If the vehicle is equipped with a stamped seatback frame, continue with the next step.
19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the
ignition switch from OFF to RUN.
20. Install the airbag fuse and then install the fuse box cover.
21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING
BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE
CABLE IS CONNECTED.
Connect the battery negative cable.
22. Position the driver seat to its original position and program the recorded preset radio stations.
THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK
FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS.
23. Position the seat cushion side shield aside as follows:
^ Pull off the lumbar support manual adjuster knob, if equipped.
^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment).
^ GENTLY unsnap the shield from the seat frame and position the shield out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10169
24. Remove and discard the lower bolt from the recliner assembly. See Figure 9.
25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft).
26. Install the seat cushion side shield as follows:
^ Align and snap the shield into place.
^ Install the two (2) removed screws.
^ Install the lumbar support adjuster knob.
27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the
ignition switch from OFF to RUN.
28. Install the airbag fuse and then install the fuse box cover.
29.
WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING
BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE
CABLE IS CONNECTED.
Connect the battery negative cable.
30. Position the driver seat to its original position and program the recorded preset radio stations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10170
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10171
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10172
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions >
Technician Safety Information
Seat Cushion: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET 8 LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
- TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions >
Technician Safety Information > Page 10177
Seat Cushion: Vehicle Damage Warnings
CAUTION:
- Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat
not secured in the vehicle may result in damaged components.
- Use care when separating the seat cushion trim cover from the hook and loop strip or the hook
and loop strip may be torn from the seat cushion foam.
- The flex mat J-clips must be Installed with the openings facing down or the seat cushion may be
damaged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation
Seat Cushion: Service and Repair Removal And Installation
With Side Air Bag
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET 8 LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10180
connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10181
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
8. Using the special tool, remove the safety belt buckle support bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10182
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
13. Remove the tie strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10183
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10184
21. Disconnect the clockspring electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
26. Remove the seat track. 27. Remove the seat backrest.
INSTALLATION
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10185
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat Systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Install the seat backrest. 2. Install the seat track. 3. Position the driver seat into the vehicle.
Install all the seat track to floor bolts and hand-tighten them.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. Connect the driver seat side air bag and power seat (if equipped) electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10186
3 Tie-strap the wire harness.
6. Connect the battery ground cable. 7. Position the driver seat rearward. 8. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
9. Tighten the driver seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
10. Move and tilt the driver seat to its highest and most forward position.
11. Tighten the driver seat rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
12. Install the driver seat rear track bolt covers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10187
13. Connect the safety belt warning indicator electrical connector.
14. Using the special tool, install the safety belt buckle support bolt.
15. Install the safety belt buckle support bolt cover. 16. Position the driver seat rearward. 17.
Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
18. Position the passenger seat forward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10188
19. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 21.
Position the passenger seat rearward.
22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
23. Install the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10189
24. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
25. Connect the clockspring electrical connector at the base of the steering column.
26. Position the lower steering column opening finish panel reinforcement and install the bolts.
27. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10190
28. Position the hood release handle and install the screws. 29. Connect the battery ground cable.
30. With all the diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
31. Check the restraint system for correct operation.
Without Side Air Bag
REMOVAL
1. Remove the seat. 2. Remove the seat track. 3. Remove the seat backrest.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
With Side Air Bag
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10191
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the passenger seat rearward.
2. Remove the passenger seat front track to floor bolts. 3. Move and tilt the front seats to their
highest and most forward position. 4. Disconnect the battery ground cable and wait at least one
minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10192
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
6. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10193
8. Using the special tool, remove the safety belt buckle support bolt.
9. Remove the passenger seat rear bolt trim covers.
10. Remove the passenger seat rear bolts. 11. Remove the passenger seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10194
14. Connect the battery ground cable. 15. Position the driver seat rearward. 16. Disconnect the
battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
17. Remove the retaining screws and position the hood release handle out of the way.
18. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
19. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10195
20. Disconnect the clockspring electrical connector at the base of the steering column.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 22. Remove the passenger air bag module.
23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 24. Connect the battery ground cable. 25. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 26. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
27. Remove the seat track. 28. Remove the seat backrest.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10196
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Install the seat backrest. 2. Install the seat track. 3. Position the passenger seat into the vehicle.
Install and hand-tighten the four seat track to floor bolts.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
4. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10197
5. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 6.
Connect the battery ground cable. 7. Position the front seats rearward. 8. With the restraint system
diagnostic tools still in place at the remaining deployable devices, prove out the air bag system.
9. Tighten the passenger seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the
battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
12. Tighten the passenger seat rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10198
13. Install the passenger seat rear track bolt covers.
14. Using the special tool, install the safety belt buckle support bolt.
15. Install the safety belt buckle support bolt cover.
16. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10199
17. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 18.
Connect the battery ground cable. 19. Position the front seats rearward. 20. Disconnect the battery
ground cable and wait at least one minute.
21. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
22. Connect the clockspring electrical connector at the base of the steering column.
23. Position the lower steering column opening finish panel reinforcement and install the bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10200
24. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
25. Position the hood release handle and install the screws.
26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
27. Install the passenger air bag module. 28. Connect the battery ground cable. 29. With all the
diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
30. Check the restraint system for correct operation.
Without Side Air Bag
REMOVAL
1. Remove the seat. 2. Remove the seat track.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10201
3. Remove the seat backrest.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
40 Percent Portion of 60/40 Split Bench
REMOVAL
1. Remove the seat. 2. Remove the seat backrest.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
50/50 Split Bench
REMOVAL
1. Fold the rear seat cushion assembly forward.
2. Remove the retaining nut from the end of the link arm and slide the link arm from the stud on the
seat cushion frame. 3. Return the seat back assembly to the upright position.
4. Remove the retaining nuts from the front floor attachment. 5. Remove the seat cushion assembly
from the vehicle.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
60 Percent Portion of 60/40 Split Bench
REMOVAL
1. Remove the seat. 2. Remove the seat backrest.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10202
Seat Cushion: Service and Repair Disassembly and Assembly
Manual, With E-Z Entry
DISASSEMBLY
1. Remove the seat cushion.
2. Disconnect the seat cushion trim cover J-clips.
3. Remove the seat cushion trim cover.
- Disconnect the seat trim cover from the hook and loop strips.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
4. Remove the seat cushion.
- Disconnect the front and rear J-clips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10203
5. Remove the flexilator.
1 Remove the flexilator to frame springs.
2 Remove the flexilator.
ASSEMBLY
1. Install the flexilator.
1 Position the flexilator.
2 Install the flexilator to frame springs.
2. Position the seat cushion trim cover on the seat cushion hook and loop strips.
3. Connect the seat cushion trim cover J-clips. 4. Install the seat cushion.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10204
Driver Side
Special Tool(s)
SPECIAL TOOL(S)
DISASSEMBLY
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10205
connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to
operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts.
3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10206
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
8. Using the special tool, remove the safety belt buckle support bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10207
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle can result in damaged components.
13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10208
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10209
21. Disconnect the clockspring electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
26. Remove the seat cushion.
27. Disconnect the seat cushion trim cover J-clips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10210
28. Remove the seat cushion frame from the seat cushion foam. 29. Invert the seat cushion trim
cover.
30. Remove the swing rods.
1 Remove and discard the hog rings.
2 Remove the swing rods.
31. Remove the seat cushion trim cover.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
32. Remove the wire harness from the seat cushion frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10211
ASSEMBLY
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Install the wire harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10212
2. Position the seat cushion trim cover.
NOTE: When installing a new seat cushion trim cover, it may be necessary to cut a hole for the
front seat back pad adjusting cable and the side air bag wiring harness. Use the old seat cushion
trim cover as a guide for the location of the hole.
3. Install the seat cushion swing rods.
1 Position the swing rods.
NOTE: Make sure the ends of the swing rods are positioned beneath the listing wires at the rear of
the seat cushion foam.
2 Install the hog rings.
4. Invert the seat cushion trim cover.
5. Connect the seat cushion trim cover J-clips. 6. Install the seat cushion. 7. Position the driver seat
into the vehicle. Install all the seat track to floor bolts and hand-tighten them.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle can result in damaged components.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10213
8. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
9. Connect the driver seat side air bag and power seat (if equipped) electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
3 Tie-strap the wire harness.
10. Connect the battery ground cable. 11. Position the driver seat rearward. 12. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
13. Tighten in the sequence shown the driver seat front track to floor bolts.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
14. Move and tilt the driver seat to its highest and most forward position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10214
15. Tighten in the sequence shown the driver seat rear track to floor bolts.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
16. Install the driver seat rear track bolt covers.
17. Connect the safety belt warning indicator electrical connector.
18. Using the special tool, install the safety belt buckle support bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10215
19. Install the safety belt buckle support bolt cover. 20. Position the driver seat rearward. 21.
Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
22. Position the passenger seat forward.
23. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
24. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10216
25. Position the passenger seat rearward.
26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
27. Install the passenger air bag module.
28. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
29. Connect the clockspring electrical connector at the base of the steering column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10217
30. Position the lower steering column opening finish panel reinforcement and install the bolts.
31. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the instrument panel. Push in the top
of the lower steering column opening finish panel to seat the retaining clips.
2 Install the screws.
32. Position the hood release handle and install the screws. 33. Connect the battery ground cable.
34. With all the diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
35. Check the restraint system for correct operation.
Passenger Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10218
Special Tool(s)
SPECIAL TOOL(S)
DISASSEMBLY
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10219
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the passenger seat rearward.
2. Remove the passenger seat front track to floor bolts. 3. Move and tilt the front seats to their
highest and most forward position. 4. Disconnect the battery ground cable and wait at least one
minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10220
6. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
8. Using the special tool, remove the safety belt buckle support bolt.
9. Remove the passenger seat rear bolt trim covers.
10. Remove the passenger seat rear bolts. 11. Remove the passenger seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10221
12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector. 14. Connect the battery ground cable. 15. Position the driver seat rearward. 16.
Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
17. Remove the retaining screws and position the hood release handle out of the way.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10222
18. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
19. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
20. Disconnect the clockspring electrical connector at the base of the steering column.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 22. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10223
23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector. 24. Connect the battery ground cable. 25. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 26. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
27. Remove the seat cushion.
28. Disconnect the seat cushion trim cover J-clips.
29. Remove the seat cushion frame from the seat cushion foam. 30. Invert the seat cushion trim
cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10224
31. Remove the swing rods.
1 Remove and discard the hog rings.
2 Remove the swing rods.
32. Remove the seat cushion trim cover.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
33. Remove the wire harness from the seat cushion frame.
ASSEMBLY
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10225
WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Install the wire harness.
2. Position the seat cushion trim cover.
NOTE: When installing a new seat cushion trim cover, it may be necessary to cut a hole for the
front seat back pad adjusting cable and the side air bag wiring harness. Use the old seat cushion
trim cover as a guide for the location of the hole.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10226
3. Install the seat cushion swing rods.
1 Position the swing rods.
NOTE: Make sure the ends of the swing rods are positioned beneath the listing wires at the rear of
the seat cushion foam.
2 Install the hog rings.
4. Invert the seat cushion trim cover.
5. Position the seat cushion foam to the seat cushion frame.
6. Connect the seat cushion trim cover J-clips. 7. Install the seat cushion. 8. Position the passenger
seat into the vehicle. Install and hand-tighten the four seat track to floor bolts.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10227
9. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
10. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 11.
Connect the battery ground cable. 12. Position the front seats rearward. 13. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
14. Tighten the passenger seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
15. Move and tilt the front seats to their highest and most forward position. 16. Disconnect the
battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10228
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
17. Tighten the passenger seat rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
18. Install the passenger seat rear track bolt covers.
19. Using the special tool, install the safety belt buckle support bolt.
20. Install the safety belt buckle support bolt cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10229
21. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
22. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 23.
Connect the battery ground cable. 24. Position the front seats rearward. 25. Disconnect the battery
ground cable and wait at least one minute.
26. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10230
27. Connect the clockspring electrical connector at the base of the steering column.
28. Position the lower steering column opening finish panel reinforcement and install the bolts.
29. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
30. Position the hood release handle and install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10231
31. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
32. Install the passenger air bag module. 33. Connect the battery ground cable. 34. With all the
diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
35. Check the restraint system for correct operation.
Without Side Air Bag
DISASSEMBLY
1. Remove the seat. 2. Remove the seat cushion.
3. Disconnect the seat backrest recliner actuator.
1 Remove the screws.
2 Disconnect the seat backrest recliner actuator.
4. Remove the seat cushion frame from the seat cushion foam.
1 Unhook the seat cushion trim cover J-clips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10232
2 Remove the seat cushion frame from the seat cushion foam.
5. Remove the seat cushion foam from the seat cushion frame.
6. Invert the seat cushion trim cover. 7. Remove the swing rod to tie-down wire hog rings from the
side swing rods (one on each side).
8. Remove and discard the hog rings.
1 Fold back the seat cushion trim cover to expose the hog rings.
2 Remove and discard the hog rings on the front and side trenches.
NOTE: The hog rings along the front of the seat are shown, the hog rings along either side are
similar.
9. Remove the swing rods.
10. Remove the power seat wiring harness.
1 Disconnect the pin-type retainers.
2 Remove the power seat wiring harness.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10233
11. Remove the flexilator.
1 Remove the flexilator springs.
2 Remove the flexilator.
12. Remove the seat backrest recliner roll pins and remove the seat backrest recliners.
13. Disconnect the seat backrest recliners from the seat backrest recliner actuator.
1 Disconnect the seat backrest recliner actuator cable housings from the seat backrest recliners.
2 Unhook the seat backrest recliner actuator cables from the seat backrest recliners.
ASSEMBLY
1. Connect the seat backrest recliners to the seat backrest recliner actuator.
1 Hook the seat backrest recliner actuator cables to the seat backrest recliners.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10234
2 Connect the seat backrest recliner actuator cable housings to the seat backrest recliners.
2. Install the seat backrest recliner roll pins.
3. Install the flexilator.
1 Position the flexilator.
2 Install the flexilator springs.
4. Install the power seat wiring harness.
1 Position the power seat wiring harness.
2 Install the pin-type retainers.
5. Install the front swing rod. 6. Install the swing rods.
NOTE: Make sure the swing rods are seated under the boarder wire in the foam near the back of
the seat cushion.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10235
7. Install the hog rings.
1 Fold back the seat cushion trim cover to the hog ring installation position.
2 Hog ring the center of the front swing rod to the tie-down rod in the seat cushion.
3 Hog ring the front swing rod to tie-down wire outboard sides.
NOTE: The hog rings along the front of the seat are shown; the hog rings along either side are
similar.
8. Hog ring the side swing rods (one on each side) to the tie-down wire.
9. Invert the seat cushion trim cover.
10. Set the hook and loop fasteners. 11. Install the seat cushion foam to the seat cushion frame.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10236
12. Install the seat cushion frame.
1 Position the seat cushion frame.
2 Hook the seat cushion trim cover J-clips.
13. Connect the seat backrest recliner actuator.
1 Connect the seat backrest recliner actuator.
2 Install the screws. Tighten until the screws are fully seated.
14. Install the seat cushion. 15. Install the seat. 16. Check the restraint system for correct operation
40 Percent Portion of 60/40 Split Bench
DISASSEMBLY
1. Remove the rear seat.
2. Remove the rear seat legs.
1 Remove the pivot bolts.
2 Remove the rear seat legs.
3. Unhook the seat cushion trim cover J-clips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10237
4. Remove the seat cushion trim cover.
- Separate the seat cushion trim cover from the hook and loop strip.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
5. Remove the seat cushion flex mat.
1 Unhook the rear flex mat J-clip.
2 Unhook the front flex mat J-clip.
3 Remove the seat cushion flex mat.
NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the
rear flex mat J-clip.
ASSEMBLY
1. Install the seat cushion flex mat.
1 Position the seat cushion flex mat.
2 Rook the front flex mat J-clip.
3 Hook the rear flex mat J-clip.
CAUTION: The flex mat J-clips must be Installed with the openings facing down or the seat cushion
may be damaged.
NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the
rear flex mat J-clip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10238
2. Position the seat cushion trim cover on the seat cushion hook and loop strips.
3. Hook the seat cushion trim cover J-clips.
4. Install the rear seat riser pivot bolts.
1 Position the rear seat legs.
2 Install the rear seat riser pivot bolts.
5. Install the seat.
NOTE: Check the restraint system for correct operation.
50/50 Split Bench
DISASSEMBLY
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10239
1. Remove the pivot legs.
1 Remove the bolts.
2 Remove the pivot legs.
2. Remove the seat cushion trim cover.
- Disconnect the pin-type retainers.
3. Remove the seat cushion foam from the seat cushion frame.
ASSEMBLY
1. To assemble, reverse the disassembly procedure.
NOTE: Check the restraint system for correct operation.
60 Percent Portion of 60/40 Split Bench
DISASSEMBLY
1. Remove the seat.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10240
2. Remove the seat cushion legs.
1 Remove the pivot bolts.
2 Remove the seat cushion legs.
3. Remove the seat cushion frame from the seat cushion foam.
1 Unhook the seat cushion trim cover J-clips.
2 Remove the seat cushion frame from the seat cushion foam.
4. Invert the seat cushion trim cover.
5. Remove the seat cushion trim cover.
- Separate the seat cushion trim cover from the hook and loop strip.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10241
6. Remove the seat cushion flex mats.
1 Unhook the rear flex mat J-clips.
2 Unhook the front flex mat J-clips.
3 Remove the seat cushion flex mats.
NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the
rear flex mat J-clip.
ASSEMBLY
1. Install the seat cushion flex mats.
1 Position the seat cushion flex mats.
2 Hook the front flex mat J-clips.
3 Hook the rear flex mat J-clips.
CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion
foam may be damaged.
NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the
rear flex mat clip.
2. Position the seat cushion trim cover on the seat cushion hook and loop strips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal And Installation > Page 10242
3. Install the seat cushion frame into the seat cushion foam.
1 Position the seat cushion frame.
2 Hook the seat cushion trim cover J-clips.
4. Install the seat cushion legs.
1 Position the seat cushion legs.
2 Install the rear seat riser pivot bolts.
5. Install the seat.
NOTE: Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions >
Technician Safety Information
Seat Track: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
- TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions >
Technician Safety Information > Page 10247
Seat Track: Vehicle Damage Warnings
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry
Seat Track: Service and Repair E-Z Entry
REMOVAL
1. Remove the front seat.
2. Remove the safety belt buckle support.
1 Remove the nut.
2 Remove the bolt.
3 Remove the safety belt buckle support.
3. Unfasten the seat backrest spring clip.
4. Remove the seat track to seat cushion front bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10250
5. Remove the front seat track.
1 Remove the seat track to seat cushion rear bolts.
2 Remove the front seat track.
INSTALLATION
1. Install the front seat track front bolts.
1 Position the front seat track.
2 Install the inboard bolt.
3 Install the outboard bolt.
2. Install the front seat track rear bolts.
1 Install the inboard bolt.
2 Install the outboard bolt.
3. Fasten the seat backrest spring clips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10251
4. Install the safety belt buckle support onto the slide bar.
1 Position the safety belt buckle support onto the slide bar.
2 Using the special tool, install the safety belt buckle support bolt.
3 Remove the safety belt buckle support from the vise.
5. Install the safety belt buckle slide bar onto the seat.
1 Position the safety belt buckle slide bar to the seat.
2 Install the nut and bolt.
6. Install the front seat. 7. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10252
Seat Track: Service and Repair Front Manual
REMOVAL
1. Remove the front seat.
2. Remove the safety belt buckle support.
1 Remove the nut.
2 Remove the bolt.
3 Remove the safety belt buckle support.
3. Remove the seat track to seat cushion front bolts.
4. Remove the front seat track.
1 Remove the seat track to seat cushion rear bolts.
2 Remove the front seat track.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10253
1. Install the front seat track front bolts.
1 Position the front seat track.
2 Install the inboard bolt.
3 Install the outboard bolt.
2. Install the front seat track rear bolts.
1 Install the inboard bolt.
2 Install the outboard bolt.
3. Install the safety belt buckle support onto the slide bar.
1 Position the safety belt buckle support onto the slide bar.
2 Using the special tool, install the safety belt buckle support bolt.
3 Remove the safety belt buckle support from the vise.
4. Install the safety belt buckle slide bar onto the seat.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10254
1 Position the safety belt buckle slide bar to the seat.
2 Install the nut and bolt.
5. Install the front seat. 6. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10255
Seat Track: Service and Repair Front Power
With Side Air Bag
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10256
connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat Systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10257
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
8. Using the special tool, remove the safety belt buckle support bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10258
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10259
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10260
21. Disconnect the clockspring electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
26. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
27. Remove the safety belt buckle support.
1 Remove the nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10261
2 Remove the bolt.
3 Remove the safety belt buckle support.
28. Disconnect the seat track wiring harness electrical connector.
29. Remove the seat track.
1 Remove the bolts.
2 Remove the seat track.
INSTALLATION
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10262
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Install the seat track.
NOTE: When installing the power seat track, start at the corner with the round hole and work
around the seat base in a horseshoe pattern.
2. Connect the seat track wiring harness electrical connectors.
3. Install the safety belt buckle support onto the slide bar.
1 Position the safety belt buckle support onto the slide bar.
2 Using the special tool, install the safety belt buckle support bolt.
3 Remove the safety belt buckle support from the vise.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10263
4. Install the safety belt buckle slide bar onto the seat.
1 Position the safety belt buckle slide bar to the seat.
2 Install the nut and bolt.
5. Position the driver seat into the vehicle. Install all the seat track to floor bolts and hand-tighten
them.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
6. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. Connect the driver seat side air bag and power seat (if equipped) electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
3 Tie-strap the wire harness.
8. Connect the battery ground cable. 9. Position the driver seat rearward.
10. With the restraint system diagnostic tools still in place at the remaining deployable devices,
prove out the air bag system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10264
11. Tighten the driver seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
12. Move and tilt the driver seat to its highest and most forward position.
13. Tighten the driver seat rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
14. Install the driver seat rear track bolt covers.
15. Connect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10265
16. Using the special tool, install the safety belt buckle support bolt.
17. Install the safety belt buckle support bolt cover. 18. Position the driver seat rearward. 19.
Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
20. Position the passenger seat forward.
21. Remove the restraint system diagnostic tool from the passenger seat side airbag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOLS IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10266
22. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 23.
Position the passenger seat rearward.
24. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
25. Install the passenger air bag module.
26. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10267
27. Connect the clockspring electrical connector at the base of the steering column.
28. Position the lower steering column opening finish panel reinforcement and install the bolts.
29. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
30. Position the hood release handle and install the screws. 31. Connect the battery ground cable.
32. With all the diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10268
33. Check the restraint system for correct operation.
Without Side Air Bag
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag delete resistor electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10269
6. Remove the safety belt buckle support bolt cover plug.
7. Using the special tool, remove the safety belt buckle support bolt.
8. Disconnect the safety belt warning indicator electrical connector.
9. Remove the driver seat rear bolt trim covers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10270
10. Remove the driver seat rear bolts. 11. Remove the driver seat from the vehicle.
12. Remove the safety belt buckle support.
1 Remove the nut.
2 Remove the bolt.
3 Remove the safety belt buckle support.
13. Disconnect the seat track wiring harness electrical connector.
14. Remove the seat track.
1 Remove the bolts.
2 Remove the seat track.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10271
1. Install the seat track.
NOTE: When installing the power seat track, start at the corner with the round hole and work
around the seat base in a horseshoe pattern.
2. Connect the seat track wiring harness electrical connectors.
3. Install the safety belt buckle support onto the slide bar.
1 Position the safety belt buckle support onto the slide bar.
2 Using the special tool, install the safety belt buckle support bolt.
3 Remove the safety belt buckle support from the vise.
4. Install the safety belt buckle slide bar onto the seat.
1 Position the safety belt buckle slide bar to the seat.
2 Install the nut and bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10272
5. Position the driver seat into the vehicle. Install all the seat track to floor bolts and hand-tighten
them.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
6. Connect the driver seat side air bag delete resistor and power seat electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag delete resistor electrical connector.
3 Tie-strap the wire harness.
7. Connect the battery ground cable. 8. Position the driver seat rearward.
9. Tighten the driver seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
10. Move and tilt the driver seat to its highest and most forward position.
11. Tighten the driver seat rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z
Entry > Page 10273
12. Install the driver seat rear track bolt covers.
13. Connect the safety belt warning indicator electrical connector.
14. Using the special tool, install the safety belt buckle support bolt.
15. Install the safety belt buckle support bolt cover. 16. Check the restraint system for correct
operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
10274
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page
10281
OASIS CODES: 201000, 201200
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Driver Side > Page 10286
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Door Lock Switch, Driver Side
Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10289
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10290
Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10291
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 10295
Power Mirror Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 10296
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams
Power Seat Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service Precautions > Technician Safety Information
Power Seat Switch: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR
BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
- TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service Precautions > Technician Safety Information > Page 10302
Power Seat Switch: Vehicle Damage Warnings
CAUTION:
- Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat
not secured in the vehicle may result in damaged components.
- To prevent damage to the side shield, the clips must be depressed in order to release the side
shield from the cushion pan.
- Use care when disconnecting the seat cushion side shield from the seat cushion frame so the
tabs on the seat cushion side shield are not damaged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Except Side Air Bags
Power Seat Switch: Testing and Inspection Except Side Air Bags
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Except Side Air Bags > Page 10305
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Except Side Air Bags > Page 10306
Power Seat Switch: Testing and Inspection With Side Air Bags
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Except Side Air Bags > Page 10307
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag
Power Seat Switch: Service and Repair With Side Air Bag
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR
BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10310
connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to
operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Position the driver seat rearward.
2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest
and most forward position. 4. Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
5. Disconnect the driver seat.
1 Remove the tie-strap.
2 Disconnect the driver seat side air bag electrical connector.
3 Disconnect the driver seat power seat track electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10311
6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
7. Remove the safety belt buckle support bolt cover plug.
8. Using the special tool, remove the safety belt buckle support bolt.
9. Disconnect the safety belt warning indicator electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10312
10. Remove the driver seat rear bolt trim covers.
11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10313
17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
18. Remove the retaining screws and position the hood release handle out of the way.
19. Remove the lower steering column opening finish panel.
1 Remove the two retaining screws from the lower steering column opening finish panel.
2 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
20. Remove the bolts and remove the lower steering column opening finish panel reinforcement.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10314
21. Disconnect the clockspring electrical connector at the base of the steering column.
22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic
tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery
ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO
DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
26. Remove the lumbar support knob.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10315
27. Remove the rear side shield screw.
28. Release the side shield clips.
CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release
the side shield from the cushion pan.
29. Unhook the side shield from the seat latch.
30. Remove the side shield.
1 Disconnect the electrical connector.
2 Remove the side shield.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10316
31. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE
DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS OR THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)
system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems.
- Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety
belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt
pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to
diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the
seats must be removed from the vehicle and the restraint system diagnostic tools must be installed
in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors.
The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
- Diagnostics may be performed on seat systems other than the side airbag or the safety belt
pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the
seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the
seats in the side airbag and safety belt pretensioner to floor connectors.
- After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10317
1. Install the 6-way power seat switch.
1 Install the 6-way power seat switch.
2 Install the screws.
2. Install the side shield.
1 Install the side shield.
2 Install the electrical connector.
3. Hook the side shield to the seat latch.
4. Install the side shield clips.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10318
5. Install the rear side shield screw.
6. Install the lumbar support knob. 7. Position the driver seat into the vehicle. Install the four seat
track to floor bolts and hand-tighten them.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
8. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10319
9. Connect the driver seat side air bag and power seat (if equipped) electrical connectors.
1 Connect the driver seat power seat track electrical connector.
2 Connect the driver seat side air bag electrical connector.
3 Tie-strap the wire harness.
10. Connect the battery ground cable. 11. Position the driver seat rearward. 12. With the restraint
system diagnostic tools still in place at the remaining deployable devices, prove out the air bag
system.
13. Tighten the driver seat front track to floor bolts in the sequence shown.
1 Tighten the front inboard bolt.
2 Tighten the front outboard bolt.
14. Move and tilt the driver seat to its highest and most forward position.
15. Tighten the driver seat rear track to floor bolts in the sequence shown.
1 Tighten the rear inboard bolt.
2 Tighten the rear outboard bolt.
16. Install the driver seat rear track bolt covers.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10320
17. Connect the safety belt warning indicator electrical connector.
18. Using the special tool, install the safety belt buckle support bolt.
19. Install the safety belt buckle support bolt cover. 20. Position the driver seat rearward. 21.
Disconnect the battery ground cable and wait at least one minute.
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE
BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY
FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO
DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
22. Position the passenger seat forward.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10321
23. Remove the restraint system diagnostic tool from the passenger seat side air bag floor
electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
24. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 25.
Position the passenger seat rearward.
26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
27. Install the passenger air bag module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10322
28. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the base of the steering column.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
29. Connect the clockspring electrical connector at the base of the steering column.
30. Position the lower steering column opening finish panel reinforcement and install the bolts.
31. Install the lower steering column opening finish panel.
1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating
the retaining clips.
2 Install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10323
32. Position the hood release handle and install the screws. 33. Connect the battery ground cable.
34. With all the diagnostic tools removed, prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
35. Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10324
Power Seat Switch: Service and Repair Without Side Air Bag
REMOVAL
1. Remove the front seat.
2. Remove the lumbar control knob, if equipped.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
5. Remove the front seat cushion side shield screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > With Side Air Bag > Page 10325
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Remove the front seat cushion side shield.
8. Remove the 6-way power seat switch.
- Remove the screws, then remove the 6-way power seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Check the restraint system for correct operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Page 10326
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Diagrams > Page 10330
Sunroof / Moonroof Switch: Service and Repair
REMOVAL
1. Position the overhead console aside.
2. Remove the roof opening panel control switch.
1 Remove the screws.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Ajar Switch
Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Ajar Switch > Page 10335
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 10336
Trunk / Liftgate Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 10337
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation
Sound Proofing / Insulation: Description and Operation
INSULATION
Insulation is installed:
- under the hood.
- above and below the instrument panel.
- at the A-pillar lower trim panel.
- over the front and rear tunnel.
- over the front and rear floor pans.
- inside the B-pillar.
- inside the C-pillar.
- inside the D-pillar (Explorer Sport).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair >
Tailgate Latch
Tailgate Latch: Service and Repair Tailgate Latch
REMOVAL
1. Remove the tailgate trim panel.
1 Remove the screws.
2 Remove the pin-type retainers.
2. Remove the tailgate latch bolts.
3. Remove the tailgate latch actuating rod guide.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair >
Tailgate Latch > Page 10346
4. Remove the tailgate latch.
1 Release the actuating rod.
2 Remove the tailgate latch.
INSTALLATION
1. To install, reverse the removal procedure.
- If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford
specification ESR-M1C159-A to lubricate the latches.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair >
Tailgate Latch > Page 10347
Tailgate Latch: Service and Repair Tailgate Latch Remote Control
REMOVAL
1. Remove the tailgate trim panel.
1 Remove the screws.
2 Remove the pin-type retainers
2. Release the tailgate latch actuating rods from the remote control.
NOTE: Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a
relaxed state with no slack.
3. Remove the tailgate latch remote control nuts. 4. Remove the tailgate latch remote control.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair >
Tailgate Latch > Page 10348
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Service and
Repair
Tailgate Lock Cylinder: Service and Repair
REMOVAL
1. Remove the tailgate release handle.
2. Remove the clip and the lock cylinder.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and
Repair
Tailgate Release Handle: Service and Repair
REMOVAL
1. Remove the tailgate trim panel.
1 Remove the screws.
2 Remove the pin-type retainers.
2. Disconnect the tailgate latch actuating rods from the remote control.
1 Open the clips.
2 Disconnect the tailgate latch actuating rods.
3. Remove the tailgate latch remote control nuts. 4. Remove the tailgate latch release handle.
- Transfer parts as necessary.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and
Repair > Page 10355
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and
Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Disconnect the driver side windshield washer hose from inside the engine compartment.
2. Remove the windshield wiper pivot arms.
1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull
the windshield wiper pivot arm from the windshield wiper pivot shaft.
3. Remove the cowl grille screw.
4. Remove the driver side cowl grille.
- Pull up on the cowl grille to disengage the clips.
5. Remove the passenger side cowl grille.
- Pull up on the cowl grille to disengage the clips and disconnect the washer hose.
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10370
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10371
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10372
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10373
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10374
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10375
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10376
Attachment III - Technical Information
Table of Contents
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10377
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10378
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10379
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10380
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10381
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10382
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10383
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10384
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10385
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10386
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10387
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10388
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10389
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10390
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10391
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10392
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10393
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10394
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10395
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10400
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10411
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10412
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10413
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10414
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10415
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10416
Attachment III - Technical Information
Table of Contents
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10417
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10418
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10419
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10420
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10421
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10422
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10423
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10424
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10425
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10426
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10427
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10428
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10429
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10430
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10431
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10432
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10433
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10434
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10435
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 03-19-12 > Sep > 03 > Recalls for Brake Switch
(Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10440
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > Page 10441
Odometer: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Component
Information > Testing and Inspection
Odometer: Testing and Inspection
To test the odometer accuracy, drive the vehicle over a measured distance of at least 16
consecutive kilometers (10 miles). Check measured distance against odometer measured distance.
Acceptable odometer measured distance is 15.5-16.7 km (9.6-10.4 miles).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Component
Information > Testing and Inspection > Page 10444
Odometer: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > System Information
> System Diagnosis
P1430 - P1434: Testing and Inspection
For diagnosis of code P1432 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > System Information
> System Diagnosis > Page 10447
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped
Power Steering Valve: Customer Interest Steering - Shudder on Low Speed Turns or When
Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10456
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10457
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10458
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10459
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10460
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10461
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb
Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb
Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Locations > Intermediate Shaft Speed
Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 10466
Transmission Speed Sensor: Locations Output Shaft Speed Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 10467
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Diagrams > Intermediate Shaft Speed
Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Diagrams > Intermediate Shaft Speed
Sensor > Page 10470
Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Diagrams > Page 10471
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Diagrams > Page 10472
Transmission Speed Sensor: Service and Repair
Output Shaft Speed (OSS) Sensor
Removal
1. Raise and support the vehicle.
2. Disconnect Output Shaft Speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > Component Information > Diagrams > Page 10473
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10479
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10480
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10481
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10482
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10483
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10484
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10485
Attachment III - Technical Information
Table of Contents
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10486
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10487
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10488
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10489
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10490
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10491
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10492
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10493
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10494
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10495
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10496
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10497
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10498
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10499
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10500
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10501
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10502
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10503
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: > 05S28S15
> Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10504
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: >
NHTSA07V336000 > Aug > 07 > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped
Power Steering Valve: Customer Interest Steering - Shudder on Low Speed Turns or When
Stopped
Article No. 03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS
OR AT STOP
FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a
steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction
between the tire and the road surface, which is amplified by the steering system. The condition will
vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION
As design changes have taken place in the steering system, it is important to note the vehicle build
date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle
build date it may be necessary to replace the power steering pump and cooler, and install a no-hole
check valve in the steering gear. Perform a thorough evacuation of air from the power steering
system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM)
to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED
OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION
PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO
CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT
OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
NOTE
PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING
DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM
THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE
STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: >
NHTSA07V336000 > Aug > 07 > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10513
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL
AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN
SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check
valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the
No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: >
NHTSA07V336000 > Aug > 07 > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10514
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump (Part
Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and
4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement
pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE
DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM
CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement
instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger
fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR.
FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing
cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a
clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the
existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove
the return line on the new cooler to be installed and connect this new fin pack assembly to the
existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section
211-02 for complete replacement instructions.
3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of
the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE
AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the
COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line.
Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the
gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT.
USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER
METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole
Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in
only one direction, without the bleeder hole that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY
RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining
the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install
the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear
(Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering
gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid
(XT-2-QDX) or equivalent.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: >
NHTSA07V336000 > Aug > 07 > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10515
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more
thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and
stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching
the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO
INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO
BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2
below, as these vehicles are production equipped with a high output displacement pump and do
not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should
replace the Power Steering Pump with a new high displacement pump Part Number
3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION
COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND
NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF)
Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine
and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir
becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the
steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH
STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be
seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of
the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE
STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED
CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other
steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough
air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand
outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the
reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power
steering noise. When bubbles are no longer rising out of the reservoir, and any power steering
system noise has ceased, shut off the engine.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: >
NHTSA07V336000 > Aug > 07 > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10516
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: >
NHTSA07V336000 > Aug > 07 > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10517
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM
Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes
Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4 Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built
After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time
To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01
4x2 Explorer Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before
8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A
Second Time) Vehicles Built After 11-07-01 But Before
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Valve: >
NHTSA07V336000 > Aug > 07 > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder
on Low Speed Turns or When Stopped > Page 10518
8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles
Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time)
Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
Disclaimer
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205
P0205 - P0209: Testing and Inspection P0205
For diagnosis of code P0205 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10522
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10523
P0205 - P0209: Testing and Inspection P0206
For diagnosis of code P0206 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10524
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10525
P0205 - P0209: Testing and Inspection P0207
For diagnosis of code P0207 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10526
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10527
P0205 - P0209: Testing and Inspection P0208
For diagnosis of code P0208 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10528
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10529
P0205 - P0209: Testing and Inspection P0209
For diagnosis of code P0209 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> System Information > System Diagnosis > P0205 > Page 10530
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 10537
Cruise Control Servo: Service and Repair
REMOVAL
1. Disconnect the electrical connector.
2. Depress the locking tab and rotate the speed control cable cap to remove.
3. Disconnect the speed control cable from the speed control servo pulley.
1 Gently push the retaining spring.
2 Disconnect the speed control cable slug.
4. Remove the bolt and the speed control servo and bracket.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 10538
5. Remove the bolts and separate the bracket from the speed control servo.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Make sure the rubber seal is fully seated onto the speed control cable cap.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement
Technical Service Bulletin # 03S03 Date: 030801
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10547
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10548
Attachment I - Administrative Information
OASIS
Use OASIS to determine if a vehicle is eligible for this recall.
Note:
Some of the vehicles affected by this program are also affected by program 03S04. Affected
customers will receive one letter describing both programs. For customer convenience please
perform both programs during one customer visit.
PROMPTLY CORRECT
Promptly correct all affected in-stock and sold vehicles on your FSA VIN Lists. Also correct other
affected vehicles identified in OASIS which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any of your affected owners whose names are not on your VIN lists but
identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date.
Note:
Your FSA VIN list may contain customer names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states provinces and countries.
Accordingly you must limit the use of this listing to the follow- up necessary to complete this action.
Advise regional office if an owner cannot be contacted or does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the
repair was performed prior to the date indicated in the reimbursement plan which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or at their option
directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121.
Dealers are also authorized to refund owner-paid emergency repairs that were performed away
from an authorized servicing dealer after the end date
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10549
specified in the reimbursement plan.
Refund Claiming Information
Program Code: 03S03
Misc. Expense: REFUND
Misc. Expense: ADMIN
Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below. For the first 30 days after program launch emergency status
orders can be placed by calling the Special Service Support Center at 1-800-325-5621.
^ For Stock Orders effective immediately follow normal order process.
^ For Interim Orders effective immediately follow normal order process.
^ For Emergency Orders within the first 30 days after launch call 1-800-325-5621. For Emergency
Orders 31 days after launch follow normal order process.
The DOR/COR for this program is 50308. This number identifies parts ordered for this recall
through the Special Service Support Center (1-800-325-5621).
USE OF "CHECKING GAUGE"
A "Checking Gauge" is utilized in this recall during Step 6 of the Technical Instructions.
Gauges will be shipped to the dealership (quantity of 4 gauges per dealer). It is expected that tools
will arrive at the dealership the week of September 2, 2003. A limited number of additional gauges
may be ordered at no-charge by calling the Special Service Support Center at 1-800-325-5621.
Alternatively, dealers can use an accurate measuring device such as digital calipers.
PARTS RETENTION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10550
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
DEALER PRICE
For latest prices, refer to DOES II or updated price book.
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
INSPECTION
1. Locate the speed control cable identification number. Read the second to last letter. See Figure
1.
^ If the letter is a "T", no service is required. Release the vehicle. If the letter is a "D", continue with
this inspection.
2. Remove the snow/ice shield. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10551
3. Visually inspect the cable for any of the following unacceptable conditions (see Figure 3):
^ Cover flared or split.
^ Core wire exposed when no tension is applied to the cable.
^ Cable is kinked.
Replace the cable if any of the above conditions are found. For replacement and adjustment
procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual.
If none of these conditions are found, continue with the next step of this procedure.
4. WARNING: BE SURE TO MARK THE STRAND COVER AT THE VERY POINT WHERE IT
ENTERS THE NOTCHED CABLE HOUSING. FAILURE TO MARK THE COVER AND MEASURE
THE DISTANCE ACCURATELY (AS OUTLINED IN STEP 6) MAY RESULT IN FAILURE TO
REPLACE AN UNACCEPTABLE CABLE.
NOTE:
Use a suitable marker such as a fine point paint marker or a felt-tipped marking pen. Brush-on
touchup paint may also be used. DO NOT use a blunt marker or one that has a worn-out tip. It
could cause your measurement to be incorrect. Whichever marking device you decide to use, it
must leave a clean, straight line at the very point where the strand cover enters the notched cable
housing. You will be measuring, in very small increments, the distance from the very edge of the
mark you make to a certain point on the cable assembly. THE MEASUREMENT MUST NOT
INCLUDE THE THICKNESS OF THE MARK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10552
Clean the cable if necessary, then using a suitable marking device, mark the strand cover at the
point where the cover enters the notched cable housing. See Figure 4.
5. Disconnect the speed control cable connector from the throttle body cam by pulling the
connector upward. See Figure 4.
6. CAUTION: When performing the following check, you will be instructed to pull the connector taut.
Use only your hand to pull the connector. DO NOT use any type of tool to do this or damage to the
cable may occur.
CAUTION:
Do not grasp the cable so tightly that you will kink the cable.
NOTE:
When pulling the connector, the strand cover may or may not be pulled out of the notched cable
housing. For the purpose of this inspection, either is acceptable.
NOTE:
The following check can be made using either the 4 mm checking gauge supplied to each
dealership or a Vernier caliper (analog dial or electronic LCD display).
Pull the connector taut (toward the front of the vehicle). See Figure 5.
A) If the strand cover does not pull out of the notched cable housing, no further service is required.
Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10553
B) If the strand cover is pulled out of the notched cable housing, using either the supplied 4 mm
checking gauge or a Vernier caliper, measure the distance from the inside edge of the mark to the
end of the exposed strand cover. Do not include the thickness of the mark when taking the
measurement. See Figures 5 and 6.
^ If the measurement is 4 mm (5/32-inch or 0.157-inch) or greater, no further service is required.
Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle.
^ If the measurement is less than 4 mm (5/32-inch or 0.157-inch), the speed control cable must be
replaced. For replacement and adjustment
procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10554
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10555
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement
Technical Service Bulletin # 03S03 Date: 030801
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10561
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10562
Attachment I - Administrative Information
OASIS
Use OASIS to determine if a vehicle is eligible for this recall.
Note:
Some of the vehicles affected by this program are also affected by program 03S04. Affected
customers will receive one letter describing both programs. For customer convenience please
perform both programs during one customer visit.
PROMPTLY CORRECT
Promptly correct all affected in-stock and sold vehicles on your FSA VIN Lists. Also correct other
affected vehicles identified in OASIS which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any of your affected owners whose names are not on your VIN lists but
identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date.
Note:
Your FSA VIN list may contain customer names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states provinces and countries.
Accordingly you must limit the use of this listing to the follow- up necessary to complete this action.
Advise regional office if an owner cannot be contacted or does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the
repair was performed prior to the date indicated in the reimbursement plan which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or at their option
directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121.
Dealers are also authorized to refund owner-paid emergency repairs that were performed away
from an authorized servicing dealer after the end date
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10563
specified in the reimbursement plan.
Refund Claiming Information
Program Code: 03S03
Misc. Expense: REFUND
Misc. Expense: ADMIN
Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below. For the first 30 days after program launch emergency status
orders can be placed by calling the Special Service Support Center at 1-800-325-5621.
^ For Stock Orders effective immediately follow normal order process.
^ For Interim Orders effective immediately follow normal order process.
^ For Emergency Orders within the first 30 days after launch call 1-800-325-5621. For Emergency
Orders 31 days after launch follow normal order process.
The DOR/COR for this program is 50308. This number identifies parts ordered for this recall
through the Special Service Support Center (1-800-325-5621).
USE OF "CHECKING GAUGE"
A "Checking Gauge" is utilized in this recall during Step 6 of the Technical Instructions.
Gauges will be shipped to the dealership (quantity of 4 gauges per dealer). It is expected that tools
will arrive at the dealership the week of September 2, 2003. A limited number of additional gauges
may be ordered at no-charge by calling the Special Service Support Center at 1-800-325-5621.
Alternatively, dealers can use an accurate measuring device such as digital calipers.
PARTS RETENTION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10564
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
DEALER PRICE
For latest prices, refer to DOES II or updated price book.
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
INSPECTION
1. Locate the speed control cable identification number. Read the second to last letter. See Figure
1.
^ If the letter is a "T", no service is required. Release the vehicle. If the letter is a "D", continue with
this inspection.
2. Remove the snow/ice shield. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10565
3. Visually inspect the cable for any of the following unacceptable conditions (see Figure 3):
^ Cover flared or split.
^ Core wire exposed when no tension is applied to the cable.
^ Cable is kinked.
Replace the cable if any of the above conditions are found. For replacement and adjustment
procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual.
If none of these conditions are found, continue with the next step of this procedure.
4. WARNING: BE SURE TO MARK THE STRAND COVER AT THE VERY POINT WHERE IT
ENTERS THE NOTCHED CABLE HOUSING. FAILURE TO MARK THE COVER AND MEASURE
THE DISTANCE ACCURATELY (AS OUTLINED IN STEP 6) MAY RESULT IN FAILURE TO
REPLACE AN UNACCEPTABLE CABLE.
NOTE:
Use a suitable marker such as a fine point paint marker or a felt-tipped marking pen. Brush-on
touchup paint may also be used. DO NOT use a blunt marker or one that has a worn-out tip. It
could cause your measurement to be incorrect. Whichever marking device you decide to use, it
must leave a clean, straight line at the very point where the strand cover enters the notched cable
housing. You will be measuring, in very small increments, the distance from the very edge of the
mark you make to a certain point on the cable assembly. THE MEASUREMENT MUST NOT
INCLUDE THE THICKNESS OF THE MARK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10566
Clean the cable if necessary, then using a suitable marking device, mark the strand cover at the
point where the cover enters the notched cable housing. See Figure 4.
5. Disconnect the speed control cable connector from the throttle body cam by pulling the
connector upward. See Figure 4.
6. CAUTION: When performing the following check, you will be instructed to pull the connector taut.
Use only your hand to pull the connector. DO NOT use any type of tool to do this or damage to the
cable may occur.
CAUTION:
Do not grasp the cable so tightly that you will kink the cable.
NOTE:
When pulling the connector, the strand cover may or may not be pulled out of the notched cable
housing. For the purpose of this inspection, either is acceptable.
NOTE:
The following check can be made using either the 4 mm checking gauge supplied to each
dealership or a Vernier caliper (analog dial or electronic LCD display).
Pull the connector taut (toward the front of the vehicle). See Figure 5.
A) If the strand cover does not pull out of the notched cable housing, no further service is required.
Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10567
B) If the strand cover is pulled out of the notched cable housing, using either the supplied 4 mm
checking gauge or a Vernier caliper, measure the distance from the inside edge of the mark to the
end of the exposed strand cover. Do not include the thickness of the mark when taking the
measurement. See Figures 5 and 6.
^ If the measurement is 4 mm (5/32-inch or 0.157-inch) or greater, no further service is required.
Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle.
^ If the measurement is less than 4 mm (5/32-inch or 0.157-inch), the speed control cable must be
replaced. For replacement and adjustment
procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10568
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10569
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Page 10570
Cruise Control Servo Cable: Adjustments
1. Remove the speed control actuator cable clip.
2. Adjust the speed control actuator cable.
1 Hold the throttle body cam in the closed position.
2 Pull on the speed control actuator cable housing to remove any slack.
3 Back off the speed control actuator cable one notch and install the clip.
NOTE: ^
The speed control actuator cable must not be pulled tight for correct operation.
^ The throttle body cam will automatically spring set to the closed position. The throttle body cam
must be in the closed position.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Page 10571
Cruise Control Servo Cable: Service and Repair
REMOVAL
Early production vehicles
1. Remove the accelerator cable snow shield.
1 Detach the cable.
2 Remove the bolts.
3 Remove the accelerator cable snow shield.
2. Separate the speed control cable from the intake manifold.
1 Remove the bolt.
2 Disconnect the cable from the throttle linkage.
Late production vehicles
3. Remove the bolts and the accelerator cable snow shield.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Page 10572
4. Separate the speed control cable from the intake manifold.
1 Disconnect the cable from the throttle linkage.
2 Depress the locking tabs and separate the speed control cable from the intake manifold.
All vehicles
5. Depress the locking tab and rotate the speed control cable cap to remove.
6. Disconnect the speed control cable from the speed control servo pulley and remove the speed
control cable.
1 Gently push the retaining spring.
2 Disconnect the speed control cable slug from the speed control servo pulley.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Page 10573
^ On early production vehicles, adjust the speed control cable.
NOTE: Make sure the rubber seal is fully seated onto the speed control cable cap.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair
Cruise Control Switch: Service and Repair
REMOVAL
1. Remove the steering wheel.
2. Remove the screws and the steering wheel rear cover.
3. Remove the ribbon harness from the clips.
4. Disconnect the horn contact electrical connectors.
5. Remove the screws and the right side horn contact.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page
10577
6. Remove the screws and the speed control switch assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10587
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10588
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10589
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10590
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10591
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10592
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10593
Attachment III - Technical Information
Table of Contents
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10594
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10595
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10596
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10597
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10598
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10599
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10600
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10601
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10602
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10603
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10604
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10605
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10606
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10607
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10608
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10609
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10610
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10611
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10612
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 >
Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 >
Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10617
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10623
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10624
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10625
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10626
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10627
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10628
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10629
Attachment III - Technical Information
Table of Contents
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10630
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10631
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10632
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10633
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10634
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
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Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10635
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10636
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10637
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10638
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10639
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10640
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10641
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10642
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10643
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10644
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10645
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10646
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10647
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10648
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control
Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10653
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Page 10654
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service Precautions > Technician Safety Information
Brake Switch (Cruise Control): Technician Safety Information
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service Precautions > Technician Safety Information > Page 10657
Brake Switch (Cruise Control): Vehicle Damage Warnings
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service Precautions > Page 10658
Brake Switch (Cruise Control): Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the speed control deactivator switch electrical connector.
3. Remove the speed control deactivator switch.
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
INSTALLATION
1. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair
Cruise Control Switch: Service and Repair
REMOVAL
1. Remove the steering wheel.
2. Remove the screws and the steering wheel rear cover.
3. Remove the ribbon harness from the clips.
4. Disconnect the horn contact electrical connectors.
5. Remove the screws and the right side horn contact.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair > Page 10665
6. Remove the screws and the speed control switch assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > Customer Interest: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning
Effort/MIL ON/DTC's Set
Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set
Article No. 01-21-13
10/29/01
^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039
CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH
EFFORT WHEN TURNING IGNITION SWITCH
^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN
TURNING IGNITION SWITCH
FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001
EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002
SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER
SPORT TRAC
LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER
ISSUE
Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent
conditions:
^ Roughness and/or excessive effort in turning the key from RUN to START position.
^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent
accessory function.
^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes
P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory.
This may be caused by a Key-In-Ignition warning chime switch.
ACTION
Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock
cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Disconnect the battery ground cable and wait at least one minute.
2. Insent the ignition key and turn it to the RUN position.
3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock
cylinder) and press the release button while pulling out the ignition switch lock cylinder.
NOTE
SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD
REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH
LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS
REQUIRED.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > Customer Interest: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning
Effort/MIL ON/DTC's Set > Page 10675
4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while
sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model
Workshop Manual, Key-in-ignition warning switch removal and installation section located in
Section 413 if additional detail is required.
5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder.
6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime
switch.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
012113A Replace The 0.3 Hr.
Key-In-Ignition Warning Chime Switch
DEALER CODING
CONDITION
BASIC PART NO. CODE
11A127 42
OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000,
208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-21-13 > Oct > 01 > Ignition Switch - High
Turning Effort/MIL ON/DTC's Set
Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL
ON/DTC's Set
Article No. 01-21-13
10/29/01
^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039
CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH
EFFORT WHEN TURNING IGNITION SWITCH
^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN
TURNING IGNITION SWITCH
FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001
EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002
SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER
SPORT TRAC
LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER
ISSUE
Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent
conditions:
^ Roughness and/or excessive effort in turning the key from RUN to START position.
^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent
accessory function.
^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes
P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory.
This may be caused by a Key-In-Ignition warning chime switch.
ACTION
Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock
cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Disconnect the battery ground cable and wait at least one minute.
2. Insent the ignition key and turn it to the RUN position.
3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock
cylinder) and press the release button while pulling out the ignition switch lock cylinder.
NOTE
SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD
REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH
LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS
REQUIRED.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-21-13 > Oct > 01 > Ignition Switch - High
Turning Effort/MIL ON/DTC's Set > Page 10681
4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while
sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model
Workshop Manual, Key-in-ignition warning switch removal and installation section located in
Section 413 if additional detail is required.
5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder.
6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime
switch.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
012113A Replace The 0.3 Hr.
Key-In-Ignition Warning Chime Switch
DEALER CODING
CONDITION
BASIC PART NO. CODE
11A127 42
OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000,
208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-24-1 > Oct > 01 >
Clutch - Pedal Stays On Floor/Does Not Disengage
Clutch Master Cylinder: All Technical Service Bulletins Clutch - Pedal Stays On Floor/Does Not
Disengage
Article No. 01-24-1
12/10/01
CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID
LEAK FROM HYDRAULIC CLUTCH LINE
FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER,
SUPER DUTY F SERIES, F-650, F-750
ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch
pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose
or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or
External Slave Cylinder.
ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External
Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the
proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or
External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure
for details.
SERVICE PROCEDURE
Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter
pins.
NOTE
MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE
SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND
F650-750.
NOTE
VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER)
REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED
ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150.
1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave
Cylinder (see previous notes) and the hydraulic line is disconnected or leaking.
2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder,
External Slave Cylinder and system bleed procedure.
3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External
Slave Cylinder.
4. Remove old quad seal from Master Cylinder and External Slave Cylinder.
5. Install new quad seal in Master Cylinder and External Slave Cylinder.
6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and
External Slave Cylinder.
7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External
Slave Cylinder).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-24-1 > Oct > 01 >
Clutch - Pedal Stays On Floor/Does Not Disengage > Page 10687
8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.
Labor Operation Claiming Chart
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7C522 39
OASIS CODES: 505200, 506000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-24-1 > Oct > 01 >
Clutch - Pedal Stays On Floor/Does Not Disengage > Page 10693
8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall.
Labor Operation Claiming Chart
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
7C522 39
OASIS CODES: 505200, 506000
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > Page 10694
Audible Warning Device: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Locations
Audible Warning Device Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Audible Warning Device Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10700
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10701
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10702
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10703
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10704
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10705
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10706
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10707
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10708
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10709
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10710
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10711
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10712
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10713
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10714
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10715
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10716
Audible Warning Device Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10717
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10718
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10719
Audible Warning Device Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10720
Audible Warning Device Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Page 10721
Audible Warning Device Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10726
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10727
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10728
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10729
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10730
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10731
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10732
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10733
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10734
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10735
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10736
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10737
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10738
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10739
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10740
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10741
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10742
Cigarette Lighter: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10743
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10744
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10745
Cigarette Lighter: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10746
Diagram 501-12-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions
Compass: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10751
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10752
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10753
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10754
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10755
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10756
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10757
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10758
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10759
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10760
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10761
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10762
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10763
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10764
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10765
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10766
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10767
Compass: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10768
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10769
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10770
Compass: Electrical Diagrams
Diagram 419-11-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 10771
Diagram 419-11-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Page 10772
Compass: Service Precautions
CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a
cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth
covers the front third and the entire width of the roof.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Page 10773
Compass: Description and Operation
A compass and outside temperature display are contained in the overhead console.
The compass and temperature display can be turned off and on by pressing the MODE switch in
the overhead console. The vehicle heading is displayed as one of N, NE, E, SE, S, SW, W, and
NW.
Compass Accuracy
Magnetic mounted devices like antennas and luggage racks should not be located on the front third
of the vehicle roof. Placing these devices near the compass will cause inaccurate directional
readings. If these devices must be used, accuracy may be improved by recalibrating the compass
while the devices are installed on the vehicle.
Driving near power lines, or driving in the area of large iron or steel structures can temporarily
change the compass heading. If the compass remains inaccurate after driving near such objects,
demagnetize the vehicle and recalibrate the compass.
Most geographic areas (zones) have a magnetic north compass point that varies slightly from the
northerly direction on maps. This variation is four degrees between the adjacent zones and will
become noticeable as the vehicle crosses multiple zones. A correct zone setting eliminates the
error. Refer to Compass Zone Adjustment.
Temperature, Outside Air
The thermometer sensor is attached to the radiator frame behind the grille. The temperature can be
displayed in Celsius or Fahrenheit by pressing the MODE switch.
If the outside temperature falls below 3.3°C (38°F), the display will alternate from ICE to the outside
temperature at a two-second rate for one minute.
The outside air temperature reading can be affected by engine heat when the vehicle is idling or
has been off for less than two hours. The compass and thermometer will limit the increase of the
displayed temperature to one degree per minute at very low speeds or immediately after the
ignition is turned on. After two minutes at a sustained speed of at least 53 km/h (33 mph), effects of
engine heat are minimal and the compass will display the current outside temperature reading.
Temperature decreases are always updated immediately.
If the outside air temperature sensor is short circuited or open, the display will show 60°C (140°F)
or -40°C (-40°F) respectively in place of temperature.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview
Compass: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the electronic compass. 2. Visually inspect for obvious
signs of mechanical and electrical damage.
Visual Inspection Chart
3. If inspection reveals an obvious concern(s) that can be readily identified, repair or install a new
component as necessary. 4. If the fault is not visually evident, determine the symptom and proceed
to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10776
Symptom Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10777
Compass: Pinpoint Tests
Connector Circuit Reference
Refer to Vehicle/Diagrams for schematic and connector information.
Pinpoint Test Notes
NOTE:
- Always set the zone, calibrate, and demagnetize a vehicle before installing a new electronic
compass module.
- After installing a new electronic compass module, always set the zone and calibrate.
Test A: Compass Is Inaccurate/Inoperative
A1 - A2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10778
A3 - A4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10779
A5 - A6
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10780
A7 - A8
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10781
A9 - A10
Test B: Outside Air Temperature Is Inaccurate/Inoperative
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10782
B1 - B3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10783
B3 - B5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10784
B5 - B6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10785
73III Automotive Meter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment
Compass: Adjustments Compass Zone Adjustment
1. Determine the zone in which the vehicle is located. 2. Press and hold the MODE button until
VAR appears on the display. Release the MODE button. 3. Momentarily press the MODE button to
increment the zone by one. Set the zone according to the map.
NOTE: After a few seconds, the compass will exit the VAR mode if the button is no longer pressed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment > Page 10788
Compass: Adjustments Calibration Adjustment
1. Start the vehicle.
NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or
structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map
lamps, wipers, etc.) and make sure all doors are closed.
2. Locate the electronic compass/temperature display on the overhead console, press and hold the
MODE button until CAL appears in the display,
then release the MODE button.
NOTE: To exit CAL mode before carrying out a compass adjustment, turn the ignition switch to the
OFF position.
3. Drive the vehicle slowly (less than 5 km/h [3 mph]) in complete circles until CAL disappears from
the display.
NOTE: If the CAL indicator does not turn off after the vehicle has been driven in a circle no more
than five times, demagnetize the vehicle and repeat the procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment > Page 10789
Compass: Adjustments Vehicle Demagnetizing
CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a
cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth
covers the front third and the entire width of the roof.
NOTE:
- The demagnetizing process requires the use of a demagnetizing coil commonly used by television
repair technicians to demagnetize television tubes.
- To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the
demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained
in the vehicle.
- During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite
the handle) is closest to the vehicle surface.
1. Demagnetize the front third of the vehicle roof.
1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle.
2 Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the
passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a
constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the
entire surface of the vehicle roof closest to the windshield. Continue the circular motion four times.
3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from
the vehicle.
4 Turn the demagnetizer off.
2. Carry out the Compass Zone Adjustment procedure. 3. Carry out the Compass Calibration
Adjustment procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Electronic With Moonroof
Compass: Service and Repair Electronic With Moonroof
REMOVAL
1. Remove the overhead console.
2. Remove the screws.
3. Disconnect the harness connector and remove the switches and the harness from the compass
module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Electronic With Moonroof > Page 10792
Compass: Service and Repair Electronic With Storage Console
REMOVAL
1. Remove the overhead console.
2. Remove the screws.
3. Push the latch and remove the compass/lamp bezel from the console housing.
4. Disconnect the harness connector and remove the switches and the harness from the compass
module.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Page 10793
73III Automotive Meter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Seats Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Disconnect the battery ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical
connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air
bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor
connector.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side floor connector. 11. Reconnect the battery ground cable.
Seats Not Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery
ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10799
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate
controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint
system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector
to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector
beneath the front seat.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
passenger side air bag electrical connector beneath
the front seat.
11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat.
12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side air bag electrical connector beneath the
front seat.
13. Reconnect the battery ground cable.
Deactivation Procedure
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will This will
reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10800
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood connected.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10801
8. Remove the driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
11. Open the glove compartment door past its stops to access the mounting screws.
12. Remove the two screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10802
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door. Reaching one hand into the glove
compartment opening push out on the passenger air bag module and separate it from the
instrument panel. Note the wire harness routing for installation.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
Vehicles without seat side air bags
16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag
bridge resistor from the side air bag to floor connector.
If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints
control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor
connector, a low resistance fault will be generated by the RCM.
Vehicles with seat side air bags and power driver seat
17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the battery ground
cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Vehicles with seat side air bags
18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side
air bags and power driver seat
19. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery
ground cable (14301) and wait at least one minute. For additional information, See: Starting and
Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10803
Vehicles with seat side air bags
20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
All vehicles
24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close
the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery
Reactivation Procedure
Reactivation
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10804
1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the
instrument panel, open the kick panel cover and remove the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the wiring Diagram Manual.
3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
Vehicles with seat side air bags
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
Vehicles with seat side air bags and power driver seat
8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10805
Vehicles with seat side air bags
9. Position the front seats rearward.
Vehicles with seat side air bags and power driver seat
10. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air
bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply
energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery
All vehicles
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical
connector.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Position the passenger air bag module into the instrument panel. Route the wire harness as noted
in removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10806
14. Install the two screws.
15. Close the glove compartment door.
16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
17. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to
the steering wheel.
18. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10807
19. Install the two steering wheel back cover plugs.
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear
blower, 15A with rear blower) to the CJB and close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to
OFF. Wait 10 seconds, then turn the key back to
ON and visually monitor the air bag indicator with the air bag modules installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an air bag
supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light.
-remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after
the ignition switch has been turned from the OFF to the ON position. This is the time required for
the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is
inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this
occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
25. Clear all continuous DTCs from the restraints control module using a scan tool.
Procedures For Repair Operations
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10808
accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10809
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10810
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10811
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10812
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Seats Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic
tool from the driver seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger
seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic
tool from the clockspring connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10813
8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable.
10. Prove out the system.
Seats Not Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring
connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove
the restraint system diagnostic tool from the floor connector beneath the front passenger seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the
passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from
the floor connector beneath the driver seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver
seat.
10. Reconnect the battery ground cable. 11. Prove out the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10814
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10815
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint
System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Testing and Inspection
Dimmer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Testing and Inspection > Page 10819
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pin 6 using a fused (10A) jumper to 12V DC power and pin 9 to
ground. Measure the voltage between pin 8 and pin 9 while rotating the thumbwell from full
illumination to no illumination. If the voltage smoothly decreases from near 12 volts to near 0 volts,
the illumination dimmer is okay. If not, replace the main light switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Driver Side
Door Switch: Diagrams Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Driver Side > Page 10824
Door Switch: Diagrams Passenger Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch
Door Switch: Service and Repair Door Ajar Switch
REMOVAL
1. Remove the door interior trim panel.
NOTE: Front door shown, rear door similar.
2. Position the watershield aside.
3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch.
- Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch > Page 10827
Door Switch: Service and Repair Door Ajar Switch-Liftgate
REMOVAL
1. Remove the liftgate latch.
2. Remove the liftgate latch ajar switch.
- Remove the screw.
INSTALLATION
1. To install, reverse the removal process.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection
Fuel Gauge: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection > Page 10831
Fuel Gauge: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Seats Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Disconnect the battery ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical
connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air
bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor
connector.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side floor connector. 11. Reconnect the battery ground cable.
Seats Not Removed
There are two deactivation procedures.
^ One procedure requires removal of the front seats. This procedure will be used when diagnosing
side air bag concerns, and also when repairing any in-seat component in vehicles equipped with
side air bags.
^ The other procedure does not require front seat removal. This procedure will be used when
diagnosing a concern not related to the Supplemental Restraint System (SRS).
1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery
ground cable.
WARNING: ^
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES,
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10837
STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE: ^
If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated using the appropriate deactivation procedure.
^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor
connectors.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the
vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed
from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor
connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle
over the road.
^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate
controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint
system diagnostic tools are installed under the seats in the side airbag floor connectors.
^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind
the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector
to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle
harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a
restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air
bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector
beneath the front seat.
10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
passenger side air bag electrical connector beneath
the front seat.
11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat.
12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the
driver side air bag electrical connector beneath the
front seat.
13. Reconnect the battery ground cable.
Deactivation Procedure
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will This will
reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10838
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood connected.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10839
8. Remove the driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
11. Open the glove compartment door past its stops to access the mounting screws.
12. Remove the two screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10840
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door. Reaching one hand into the glove
compartment opening push out on the passenger air bag module and separate it from the
instrument panel. Note the wire harness routing for installation.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
electrical connector.
Vehicles without seat side air bags
16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag
bridge resistor from the side air bag to floor connector.
If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints
control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor
connector, a low resistance fault will be generated by the RCM.
Vehicles with seat side air bags and power driver seat
17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the battery ground
cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Vehicles with seat side air bags
18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side
air bags and power driver seat
19. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery
ground cable (14301) and wait at least one minute. For additional information, See: Starting and
Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10841
Vehicles with seat side air bags
20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector.
21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical
connector.
22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector.
23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical
connector.
All vehicles
24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close
the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery
Reactivation Procedure
Reactivation
All vehicles
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10842
1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the
instrument panel, open the kick panel cover and remove the restraints control
module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For
additional information, refer to the wiring Diagram Manual.
3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, See: Starting and Charging/Battery
Vehicles with seat side air bags
4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical
connector.
5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness.
6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical
connector.
7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness.
Vehicles with seat side air bags and power driver seat
8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable. For additional information, See: Starting and Charging/Battery
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10843
Vehicles with seat side air bags
9. Position the front seats rearward.
Vehicles with seat side air bags and power driver seat
10. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air
bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply
energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery
All vehicles
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag electrical connector.
12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical
connector.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Position the passenger air bag module into the instrument panel. Route the wire harness as noted
in removal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10844
14. Install the two screws.
15. Close the glove compartment door.
16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector at the top of the steering column.
17. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to
the steering wheel.
18. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10845
19. Install the two steering wheel back cover plugs.
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear
blower, 15A with rear blower) to the CJB and close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to
OFF. Wait 10 seconds, then turn the key back to
ON and visually monitor the air bag indicator with the air bag modules installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an air bag
supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light.
-remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after
the ignition switch has been turned from the OFF to the ON position. This is the time required for
the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is
inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this
occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
25. Clear all continuous DTCs from the restraints control module using a scan tool.
Procedures For Repair Operations
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10846
accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
7. Remove the two steering wheel back cover plugs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10847
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10848
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10849
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10850
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Seats Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic
tool from the driver seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger
seat floor connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic
tool from the clockspring connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10851
8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable.
10. Prove out the system.
Seats Not Removed
1. Disconnect the battery ground cable.
WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED
AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO
AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY.
2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to
deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring
connector.
^ Reconnect the electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove
the restraint system diagnostic tool from the floor connector beneath the front passenger seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the
passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from
the floor connector beneath the driver seat.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver
seat.
10. Reconnect the battery ground cable. 11. Prove out the system.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10852
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10853
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint
System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Service and Repair
Instrument Panel Bulb: Service and Repair
REMOVAL
WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF
INCORRECTLY HANDLED. WEAR EYE PROTECTION WHEN INSTALLING NEW
ILLUMINATION BULBS.
1. Remove the instrument cluster.
2. Remove the illumination sockets and bulbs.
3. Remove the indicator sockets and bulbs.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Service and Repair
Instrument Panel Circuit Board: Service and Repair
REMOVAL
WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF
INCORRECTLY HANDLED. WEAR EYE PROTECTION WHEN INSTALLING NEW BULBS.
CAUTION: If gauges are being removed from the cluster assembly, do not remove the gauge
pointers. Magnetic gauges cannot be recalibrated.
1. Remove the instrument cluster; refer to Instrument Panel. 2. Remove the illumination and
indicator bulbs; refer to Warning Indicator Bulb. 3. Remove the gauges; refer to Gauges.
4. Remove the 19 instrument gauge clips.
NOTE: New gauge clips must be used for assembly.
5. Remove the instrument cluster printed circuit.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel
Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel
Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10868
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel
Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10869
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel
Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10870
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement >
Page 10876
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement >
Page 10877
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement >
Page 10878
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel
Illumination Control Module > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel
Illumination Control Module > Component Information > Locations > Page 10882
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions
Lamp Out Indicator: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10887
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10888
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10889
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10890
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10891
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10892
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10893
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10894
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10895
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10896
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10897
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10898
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10899
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10900
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10901
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10902
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10903
Lamp Out Indicator: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10904
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10905
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10906
Lamp Out Indicator: Electrical Diagrams
Diagram 413-09-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10907
Diagram 413-09-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10908
Diagram 413-09-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10909
Diagram 413-09-00-4
Diagram 413-09-00-5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10910
Diagram 413-09-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10911
Diagram 413-09-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10912
Diagram 413-09-00-8
Diagram 413-09-00-9
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10913
Diagram 413-09-00-10
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR LAMP (MIL)
Malfunction Indicator Lamp (MIL)
Check Engine, Service Engine Soon Or ISO Standard Engine Symbol
The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control
Module (PCM) has detected an OBD II emission-related component or system fault. When this
occurs, an OBD II Diagnostic Trouble Code (DTC) will be set.
^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or ISO standard engine symbol (Figure 16).
^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position.
^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster
proveout for approximately 4 seconds.
^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present.
- The instrument cluster will illuminate the MIL if the PCM does not send a control message to the
instrument cluster.
- The PCM is operating in the Hardware Limited Operation Strategy (HLOS).
- The MIL circuit is shorted to ground.
^ If the MIL remains off (during the bulb check): Bulb is damaged.
- MIL circuit is open.
^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three
consecutive drive cycles must be completed without a fault.
^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection.
^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist.
^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground
in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection
Odometer: Testing and Inspection
To test the odometer accuracy, drive the vehicle over a measured distance of at least 16
consecutive kilometers (10 miles). Check measured distance against odometer measured distance.
Acceptable odometer measured distance is 15.5-16.7 km (9.6-10.4 miles).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > Page 10920
Odometer: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair > Resetting Oil Change Reminder Lamp
Oil Change Reminder Lamp: Service and Repair Resetting Oil Change Reminder Lamp
Oil Change Reset
Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized
oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of
12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL
CHANGE RESET control for five seconds. The message center will count down for five seconds.
After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have
established a personalized oil reset percentage, the display will show that percentage instead of
100%.) This reset procedure should be performed only after an oil change to ensure accurate oil
life indications.
Your personalized oil reset percentage allows you to establish a smaller oil change interval than
the manufacturer's recommended interval. To establish your personalized oil reset percentage:
1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display
is still counting gown the five seconds to
reset. The display will change to START OIL LIFE AT XXX%.
2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil
reset percentage you desire. Your choices are
100%, 90%, 80%, 70%, 60%, 50% 40% and 30%.
3. Press the RESET control to complete the procedure. Pressing any control other than RESET of
OIL CHANGE RESET will abort this
procedure and will not establish your new personalized oil reset percentage.
When your personalized oil reset percentage has been established, it will be used beginning with
the completion of your next OIL CHANGE RESET procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair > Resetting Oil Change Reminder Lamp > Page 10925
Oil Change Reminder Lamp: Service and Repair No Reset Oil Life Mode
The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
With Instrument Gauge System Tester attached to the oil pressure switch connector and the
ignition switch lock cylinder in the RUN position (engine not running), set instrument Gauge System
Tester to infinite resistance. The center line of the pointer should fall on or below the L (low) mark.
Short the connector directly to engine ground. The centerline of the pointer should fall slightly
above mid-scale.
^ If the oil pressure gauge tests within calibration, install a new oil pressure switch.
^ If the oil pressure gauge still tests out of calibration, install a new gauge.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Testing and Inspection > Page 10929
Oil Pressure Gauge: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Locations
Audible Warning Device Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions
Audible Warning Device Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10942
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10943
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10944
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10945
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10946
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10947
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10948
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10949
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10950
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10951
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10952
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10953
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10954
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10955
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10956
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10957
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10958
Audible Warning Device Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10959
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10960
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10961
Audible Warning Device Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 10962
Audible Warning Device Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Page 10963
Audible Warning Device Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument
Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument
Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10972
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument
Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10973
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument
Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10974
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
Technical Service Bulletin # 02-23-4 Date: 021125
Engine Controls - DTC P1635 Set After PCM/IC Replacement
Article No. 02-23-4
11/25/02
^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER
POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY
^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR
INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY
^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL
MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE
VEHICLES ONLY
FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E
SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002
EXPLORER
LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 2002 MOUNTAINEER
Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify
build dates for Explorer.
This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to
2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP)
Louisville Assembly Plant built before 3/4/2002 only.
ISSUE
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or
Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module
(PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID)
block that must be programmed when replacing the PCM.
ACTION
As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM. Failure to perform the proper
Programmable Module Installation procedure may generate fault code: P1639 VID Block not
programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following
procedures to ensure the PCM is properly configured.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
> Page 10980
Disclaimer
Service Procedure
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one
of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly
configured.
NOTE
THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH
CABLE.
Procedure A - NGS PREFERRED Method To Prevent P1635/P1639
1. With the original PCM installed and using the NGS service card, select "Programmable Module
Installation".
2. Select PCM from the module list.
3. Select "Retrieve Module Config-Old ECU".
4. After the Module data has been stored, install the new PCM, press CANCEL to return to the
menu and select "Restore Module Config-New ECU".
This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the
original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If
the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step
a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and
manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data
has been entered, continue to Step 4 above.
Procedure B - NGS Alternative Method
1. Using NGS service card, select "Service Bay Functions".
2. Select PCM from the module list.
3. Select "Module Configuration".
4. Select "94-02 EECV & PTEC-By TSB".
5. Cycle ignition as directed by NGS.
6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be
updated.
Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the
NGS Service Function Card may not be able to configure the PCM due to the need to reprogram
the module
1. Create an NGS Flash Card with the correct calibration (Tear Tag).
2. Start the reprogramming process. (you will be notified that the vehicle already has the latest
calibration).
3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block
data).
4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module.
Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and
P1639/P1635 is set
Using WDS with B11 or later software and ignition in OFF position:
1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash).
2. Select "16 PIN", select "All others, except those below", press TICK.
3. Screen shows installation of cable, press TICK.
4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
> Page 10981
5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and
gives you a "YES" selection and a "NO" selection; select "NO".
6. Make sure the key is still OFF. Press TICK.
7. Screen then shows turn ignition ON, Now turn ignition to ON.
8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of
previous sessions to check if the vehicle was previously identified; press TICK.
9. Select "None of the above".
10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please
enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK.
NOTE
PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE
FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING
NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO
BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT
FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL.
11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the
part number and enter the last (2 or 3) digits of the part number; press TICK.
12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical
interference and battery drain". Press TICK
14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen
shows "Please wait" and progress bar moving at bottom of screen.
15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows
"Downloading data" with a progress bar.
16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK.
17. Screen shows "This module requires some configuration settings"; manually select those
parameters for your vehicle; press TICK.
18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK.
19. Screen shows selection of parameters:
^ 4X4 low range input - (PCM)? = Yes or No?
^ Manual shift on the fly - (PCM)? = manual or not manual?
^ Tire size? = Selection of tire sizes
^ Axle Ratio? = Selection of axle ratios
Choose the correct information for your vehicle; press TICK.
NOTE
EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS
SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION
OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS.
20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK.
21. Screen shows "Set ignition switch to ON"; turn ignition ON.
22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press
Tick.
23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK.
24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay;
press Tick.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement
> Page 10982
25. Screen shows "Install calibration label press TICK.
26. Screen shows "Set ignition switch to ON"; turn ignition ON.
27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required";
press TICK.
28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from
vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return
back to delete sessions menu. Delete the session and return to main screen on WDS.
29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and
confirm only P1000 is present.
30. Verify repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Panel Illumination Control Module > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Panel Illumination Control Module > Component Information > Locations > Page 10986
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Information > Application and ID
Seat Belt Reminder Lamp: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Testing and Inspection
Dimmer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Testing and Inspection > Page 10994
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pin 6 using a fused (10A) jumper to 12V DC power and pin 9 to
ground. Measure the voltage between pin 8 and pin 9 while rotating the thumbwell from full
illumination to no illumination. If the voltage smoothly decreases from near 12 volts to near 0 volts,
the illumination dimmer is okay. If not, replace the main light switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Driver Side
Door Switch: Diagrams Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Driver Side > Page 10999
Door Switch: Diagrams Passenger Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch
Door Switch: Service and Repair Door Ajar Switch
REMOVAL
1. Remove the door interior trim panel.
NOTE: Front door shown, rear door similar.
2. Position the watershield aside.
3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch.
- Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 11002
Door Switch: Service and Repair Door Ajar Switch-Liftgate
REMOVAL
1. Remove the liftgate latch.
2. Remove the liftgate latch ajar switch.
- Remove the screw.
INSTALLATION
1. To install, reverse the removal process.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection
Speedometer Head: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > Page 11009
Speedometer Head: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection
Tachometer: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > Page 11013
Tachometer: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection
Temperature Gauge: Testing and Inspection
1. Disconnect water temperature indicator sender unit C1061. Connect one lead of Instrument
Gauge System Tester to water temperature indicator
sender unit C1061, circuit 39 (RD/WH), harness side and the other lead to ground.
2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine
coolant temperature gauge should indicate C (cold).
Key OFF.
3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge pointer should be in the one
quarter range to mid-range. Key OFF.
4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge should indicate H (hot). Key
OFF. Return to the Pinpoint Test. See: Testing and Inspection/Instrument Cluster/Pinpoint Tests
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Page 11017
Temperature Gauge: Service and Repair
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component
Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component
Information > Diagrams > Page 11021
Temperature Sensor (Gauge): Service and Repair
Sender Unit-Water Temperature Indicator
Removal and Installation
1. Partially drain the cooling system. 2. Remove the thermostat.
3. Disconnect the electrical connector.
4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal
procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T >
Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams > Digital Transmission Range Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams > Digital Transmission Range Sensor > Page 11032
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins >
Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling
Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins >
Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11041
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling
Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page
11047
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11050
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11051
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11052
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11053
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11054
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11055
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11056
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11057
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11058
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11059
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11060
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11061
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11062
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11063
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11064
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11065
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11066
Brake Lamp: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11067
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11068
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11069
Brake Lamp: Electrical Diagrams
DETAILED DIAGRAMS
Diagram 417-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11070
Diagram 417-01-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11071
Diagram 417-01-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11072
Diagram 417-01-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11073
Diagram 417-01-00-5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11074
Diagram 417-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11075
Diagram 417-01-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11076
Diagram 417-01-00-8
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11077
Diagram 417-01-00-9
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11078
Diagram 417-01-00-10
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11079
Diagram 417-01-00-19
Diagram 417-01-00-20
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11080
Diagram 417-01-00-21
RELATED DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11081
Diagram 413-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11082
Diagram 417-04-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Brake Lamp: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
Visual Inspection Chart
3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart.
See: Symptom Related Diagnostic Procedures
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11085
Symptom Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11086
Brake Lamp: Pinpoint Tests
G1 - G2
Test H: One Or More Stoplamps Are Inoperative
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11087
H1 - H2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11088
H2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11089
H3 - H4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11090
H4 - H5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11091
H6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11092
H7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page
11093
73III Automotive Meter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component
Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component
Information > Diagrams > Page 11097
Brake Pedal Position Switch: Description and Operation
BRAKE PEDAL POSITION SWITCH
Typical Brake Pedal Position Switch
The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the
transmission torque converter clutch and on some applications as an input to the idle speed control
for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery
positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch
signal is broadcast over the SCP link via another module to be received by the PCM.
On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all
stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor
in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has
failed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component
Information > Diagrams > Page 11098
Brake Pedal Position Switch: Service and Repair
REMOVAL
1. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
2. Remove the BPP switch.
1 Remove the self-locking pin.
2 Remove the spacer.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb >
Component Information > Service and Repair
Center Mounted Brake Lamp Bulb: Service and Repair
REMOVAL
1. Remove the liftgate glass. Refer to Windows.
NOTE: The high mounted stoplamp bulb is not repairable. Install a new high mounted stoplamp as
an assembly.
2. Remove the tape.
3. Remove the three nuts.
1 Disconnect wiring harness tab.
2 Remove the nuts.
4. Remove the high-mounted stoplamp.
1 Disconnect the electrical connector.
2 Remove the high-mounted stoplamp.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Diagrams > Page 11113
Courtesy Lamp Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Diagrams > Page 11114
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Locations > Page 11119
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Locations > Page 11120
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the Daytime Running Lamps (DRL) control module.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Testing and Inspection
Dimmer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Testing and Inspection > Page
11124
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pin 6 using a fused (10A) jumper to 12V DC power and pin 9 to
ground. Measure the voltage between pin 8 and pin 9 while rotating the thumbwell from full
illumination to no illumination. If the voltage smoothly decreases from near 12 volts to near 0 volts,
the illumination dimmer is okay. If not, replace the main light switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 11128
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 11129
Battery Discharge Protection Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 11130
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Dome Lamp: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11135
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11136
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11137
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11138
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11139
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11140
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11141
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11142
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11143
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11144
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11145
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11146
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11147
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11148
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11149
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11150
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11151
Dome Lamp: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11152
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11153
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11154
Dome Lamp: Electrical Diagrams
Diagram 417-02-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11155
Diagram 417-02-00-3
Diagram 417-02-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 11156
Dome Lamp: Service and Repair
REMOVAL
1. Disconnect the battery.
2. Remove the lamp lens.
1 Use a thin-bladed tool to carefully pry the dome lamp lens out. ^
Install a new bulb if necessary.
3. Remove the lamp.
1 Remove the screws.
2 Lower the lamp, disconnect the electrical connector and remove the lamp from the vehicle.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Driver Side
Door Switch: Diagrams Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Driver Side > Page
11161
Door Switch: Diagrams Passenger Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch
Door Switch: Service and Repair Door Ajar Switch
REMOVAL
1. Remove the door interior trim panel.
NOTE: Front door shown, rear door similar.
2. Position the watershield aside.
3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch.
- Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch > Page 11164
Door Switch: Service and Repair Door Ajar Switch-Liftgate
REMOVAL
1. Remove the liftgate latch.
2. Remove the liftgate latch ajar switch.
- Remove the screw.
INSTALLATION
1. To install, reverse the removal process.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Fog Lamp Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Fog Lamp Relay > Page 11171
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Page 11172
Fog/Driving Lamp Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Page 11173
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information >
Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information >
Diagrams > Page 11177
Fog/Driving Lamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
3. Remove the fog lamp switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the fog lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations > Page 11182
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations > Page 11183
Hazard Flasher Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations > Page 11184
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams
Hazard Warning Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 11188
Hazard Warning Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 11189
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service
Precautions > Technician Safety Information
Headlamp Bulb: Technician Safety Information
WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY
SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED.
HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING
THE GLASS ENVELOPE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service
Precautions > Technician Safety Information > Page 11195
Headlamp Bulb: Vehicle Damage Warnings
CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new
bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb
performance. Contaminants may enter the headlamp where they can settle on the lens and
reflector. Never turn the headlamps on with the bulb removed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service
Precautions > Page 11196
Headlamp Bulb: Service and Repair
REMOVAL
WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY
SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED.
HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING
THE GLASS ENVELOPE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new
bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb
performance. Contaminants may enter the headlamp where they can settle on the lens and
reflector. Never turn the headlamps on with the bulb removed.
1. Remove the headlamp assembly.
2. Rotate the headlamp bulb retainer counterclockwise and remove.
3. Remove the headlamp bulb.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams
Headlamp Dimmer Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 11200
Headlamp Dimmer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 11201
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11205
Headlamp Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11206
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11207
Headlamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel center finish panel.
1 Remove the screws.
2 Remove the instrument panel center finish panel. ^
Disconnect electrical connectors.
3. Remove the hood latch release handle.
1 Remove the screws.
2 Remove the hood latch release handle.
4. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11208
5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the
column gear shift lever out of the way.
7. Position the cluster finish panel aside.
1 Remove the screws.
2 Position the cluster finish panel aside.
8. Remove the cluster finish panel.
1 Disconnect the electrical connectors and remove the headlamp switch knob.
2 Remove the cluster finish panel.
9. Remove the headlamp switch.
1 Remove the screws.
2 Remove the headlamp switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11209
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11214
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11215
Horn Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11216
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair
Horn Switch: Service and Repair
REMOVAL
1. Remove the driver side air bag.
2. Remove the switch.
1 Disconnect the horn wire (BK) from the switches.
2 Remove the screws and the switch.
INSTALLATION
1. To install, reverse the removal procedure.
^ Prove out the air bag system; refer to Air Bag Systems.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations
Interior Lighting Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11225
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11226
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11227
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11228
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11229
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11230
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11231
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11232
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11233
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11234
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11235
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11236
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11237
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11238
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11239
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11240
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11241
Interior Lighting Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11242
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11243
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11244
Interior Lighting Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11245
Interior Lighting Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page
11246
Interior Lighting Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11250
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11251
Interior Lighting Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11252
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions
Lamp Out Indicator: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11257
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11258
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11259
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11260
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11261
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11262
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11263
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11264
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11265
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11266
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11267
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11268
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11269
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11270
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11271
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11272
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11273
Lamp Out Indicator: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11274
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11275
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11276
Lamp Out Indicator: Electrical Diagrams
Diagram 413-09-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11277
Diagram 413-09-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11278
Diagram 413-09-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11279
Diagram 413-09-00-4
Diagram 413-09-00-5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11280
Diagram 413-09-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11281
Diagram 413-09-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11282
Diagram 413-09-00-8
Diagram 413-09-00-9
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram
Information and Instructions > Page 11283
Diagram 413-09-00-10
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions
License Plate Lamp: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11288
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11289
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11290
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11291
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11292
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11293
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11294
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11295
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11296
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11297
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11298
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11299
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11300
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11301
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11302
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11303
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11304
License Plate Lamp: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11305
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11306
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11307
License Plate Lamp: Connector Views
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11308
License Plate Lamp: Electrical Diagrams
DETAILED DIAGRAMS
Diagram 417-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11309
Diagram 417-01-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11310
Diagram 417-01-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11311
Diagram 417-01-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11312
Diagram 417-01-00-5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11313
Diagram 417-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11314
Diagram 417-01-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11315
Diagram 417-01-00-8
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11316
Diagram 417-01-00-9
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11317
Diagram 417-01-00-10
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11318
Diagram 417-01-00-19
Diagram 417-01-00-20
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11319
Diagram 417-01-00-21
RELATED DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11320
Diagram 413-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11321
Diagram 417-04-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 11322
License Plate Lamp: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Parking Lamp; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions
Map Light: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11327
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11328
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11329
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11330
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11331
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11332
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11333
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11334
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11335
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11336
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11337
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11338
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11339
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11340
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11341
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11342
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11343
Map Light: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11344
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11345
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11346
Map Light: Electrical Diagrams
Diagram 417-02-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions > Page 11347
Diagram 417-02-00-3
Diagram 417-02-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Page 11348
Map Light: Service and Repair
REMOVAL
1. Disconnect the battery.
2. Remove the lamp lens.
1 Use a thin-bladed tool to carefully pry the dome lamp lens out. ^
Install a new bulb if necessary.
3. Remove the lamp.
1 Remove the screws.
2 Lower the lamp, disconnect the electrical connector and remove the lamp from the vehicle.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
Diagram 700-01-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams
> Early Production
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams
> Early Production > Page 11355
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing
and Inspection > Early Production
Parking Lamp Relay: Testing and Inspection Early Production
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing
and Inspection > Early Production > Page 11358
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing
and Inspection > Early Production > Page 11359
Parking Lamp Relay: Testing and Inspection Late Production
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing
and Inspection > Early Production > Page 11360
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 11365
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 11366
Battery Discharge Protection Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 11367
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams > Page 11371
Courtesy Lamp Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams > Page 11372
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations > Page 11376
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations > Page 11377
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the Daytime Running Lamps (DRL) control module.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Fog Lamp Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Fog Lamp Relay > Page 11383
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Page 11384
Fog/Driving Lamp Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Page 11385
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 11389
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 11390
Hazard Flasher Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 11391
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 11395
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 11396
Horn Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 11397
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Locations
Interior Lighting Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11403
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11404
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11405
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11406
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11407
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11408
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11409
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11410
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11411
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11412
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11413
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11414
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11415
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11416
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11417
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11418
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11419
Interior Lighting Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11420
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11421
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11422
Interior Lighting Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11423
Interior Lighting Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Page 11424
Interior Lighting Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations > Page 11428
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations > Page 11429
Interior Lighting Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations > Page 11430
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Diagram 700-01-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Diagrams > Early Production
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Diagrams > Early Production > Page 11436
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Early Production
Parking Lamp Relay: Testing and Inspection Early Production
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Early Production > Page 11439
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Early Production > Page 11440
Parking Lamp Relay: Testing and Inspection Late Production
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Early Production > Page 11441
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Page 11445
Trailer Lighting Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Page 11446
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Diagrams > Page 11450
Turn Signal Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Diagrams > Page 11451
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Digital Transmission Range Sensor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams > Digital Transmission Range Sensor > Page 11458
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch
<--> [Brake Light Switch] > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch
<--> [Brake Light Switch] > Component Information > Diagrams > Page 11462
Brake Pedal Position Switch: Description and Operation
BRAKE PEDAL POSITION SWITCH
Typical Brake Pedal Position Switch
The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the
transmission torque converter clutch and on some applications as an input to the idle speed control
for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery
positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch
signal is broadcast over the SCP link via another module to be received by the PCM.
On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all
stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor
in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has
failed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch
<--> [Brake Light Switch] > Component Information > Diagrams > Page 11463
Brake Pedal Position Switch: Service and Repair
REMOVAL
1. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
2. Remove the BPP switch.
1 Remove the self-locking pin.
2 Remove the spacer.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Driver Side
Door Switch: Diagrams Driver Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Driver Side > Page 11468
Door Switch: Diagrams Passenger Side
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch
Door Switch: Service and Repair Door Ajar Switch
REMOVAL
1. Remove the door interior trim panel.
NOTE: Front door shown, rear door similar.
2. Position the watershield aside.
3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch.
- Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch > Page 11471
Door Switch: Service and Repair Door Ajar Switch-Liftgate
REMOVAL
1. Remove the liftgate latch.
2. Remove the liftgate latch ajar switch.
- Remove the screw.
INSTALLATION
1. To install, reverse the removal process.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch >
Component Information > Diagrams > Page 11475
Fog/Driving Lamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
3. Remove the fog lamp switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the fog lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams
Hazard Warning Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 11479
Hazard Warning Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 11480
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams
Headlamp Dimmer Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 11484
Headlamp Dimmer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 11485
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11489
Headlamp Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11490
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11491
Headlamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel center finish panel.
1 Remove the screws.
2 Remove the instrument panel center finish panel. ^
Disconnect electrical connectors.
3. Remove the hood latch release handle.
1 Remove the screws.
2 Remove the hood latch release handle.
4. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11492
5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the
column gear shift lever out of the way.
7. Position the cluster finish panel aside.
1 Remove the screws.
2 Position the cluster finish panel aside.
8. Remove the cluster finish panel.
1 Disconnect the electrical connectors and remove the headlamp switch knob.
2 Remove the cluster finish panel.
9. Remove the headlamp switch.
1 Remove the screws.
2 Remove the headlamp switch.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11493
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Service and Repair
Horn Switch: Service and Repair
REMOVAL
1. Remove the driver side air bag.
2. Remove the switch.
1 Disconnect the horn wire (BK) from the switches.
2 Remove the screws and the switch.
INSTALLATION
1. To install, reverse the removal procedure.
^ Prove out the air bag system; refer to Air Bag Systems.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams
Turn Signal Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11500
Turn Signal Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11501
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11502
Turn Signal Switch: Service and Repair
Multifunction Switch
Removal and Installation
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11503
5. Remove the multifunction switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multifunction switch.
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch >
Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch >
Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 11508
OASIS CODES: 201000, 201200
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Tail Lamp: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11513
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11514
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11515
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11516
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11517
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11518
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11519
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11520
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11521
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11522
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11523
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11524
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11525
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11526
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11527
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11528
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11529
Tail Lamp: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11530
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11531
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11532
Tail Lamp: Electrical Diagrams
DETAILED DIAGRAMS
Diagram 417-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11533
Diagram 417-01-00-2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11534
Diagram 417-01-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11535
Diagram 417-01-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11536
Diagram 417-01-00-5
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11537
Diagram 417-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11538
Diagram 417-01-00-7
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11539
Diagram 417-01-00-8
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11540
Diagram 417-01-00-9
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11541
Diagram 417-01-00-10
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11542
Diagram 417-01-00-19
Diagram 417-01-00-20
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11543
Diagram 417-01-00-21
RELATED DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11544
Diagram 413-00-00-3
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11545
Diagram 417-04-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11546
Tail Lamp: Testing and Inspection
For Further information regarding the diagnosis of this component and the system that it is a part
of, please refer to Parking Lamp; Testing and Inspection.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11547
Tail Lamp: Service and Repair
REMOVAL
1. Open the rear liftgate.
2. Remove the two screws.
^ Pull the lamp assembly rearward.
^ Disconnect the electrical connectors.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the trailer tow lamps. 2. Verify the exterior lighting
system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually
inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) fuse: 3 (7.5A)
- 7 (7.5A)
- 36 (15A)
^ Circuitry
^ Trailer tow relay
^ Bulb(s)
4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart.
See: Symptom Related Diagnostic Procedures
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11552
Symptom Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11553
Trailer Lamps: Pinpoint Tests
Connector Circuit Reference
Refer to Vehicle/Diagrams for schematic and connector information.
V1
W1 - W2
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Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11554
W2
X1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11555
X1
Y1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11556
Z1 - Z2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11557
Z2
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11558
73III Automotive Meter
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Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page
11559
73III Automotive Meter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Page 11563
Trailer Lighting Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Page 11564
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Trunk Lamp: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11569
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11570
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11571
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11572
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11573
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11574
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11575
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11576
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11577
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11578
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11579
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11580
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11581
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11582
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11583
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11584
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11585
Trunk Lamp: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11586
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11587
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11588
Trunk Lamp: Electrical Diagrams
Diagram 417-02-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11589
Diagram 417-02-00-3
Diagram 417-02-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams >
Page 11594
Turn Signal Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams >
Page 11595
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams
Turn Signal Switch: Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11599
Turn Signal Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11600
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11601
Turn Signal Switch: Service and Repair
Multifunction Switch
Removal and Installation
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11602
5. Remove the multifunction switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multifunction switch.
6. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 11608
OASIS CODES: 201000, 201200
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Vanity Lamp: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11613
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11614
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11615
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11616
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11617
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11618
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11619
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11620
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11621
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11622
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11623
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11624
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11625
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11626
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11627
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11628
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11629
Vanity Lamp: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11630
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11631
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11632
Vanity Lamp: Electrical Diagrams
Diagram 417-02-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11633
Diagram 417-02-00-3
Diagram 417-02-00-4
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11639
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11640
Heated Glass Element Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11641
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component
Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair
Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair
TSB 04-24-5
12/13/04
REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR
FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria,
Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005
Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape
2004-2005 F-150, Freestar 2005 Escape Hybrid
LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator
2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego
1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 04-18-9 to update vehicle applications and service procedure.
ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid
lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the
rear window glass.
ACTION Follow the diagnostic and repair procedures included in this article to inspect and service
rear defroster grid lines, integral antenna concerns or broken terminal tabs.
SERVICE PROCEDURE
Warrantable/Non Warrantable repairs
Warrantable grid line repairs typically can be identified by one inoperative grid line with a small
discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are
scratched or have the silver material removed are not warrantable and should be addressed with
the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable
repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated
Back Lite Damageability Job Aid for additional information and examples of defects and damage.
NOTE
THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE
GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY
APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11649
THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS
EXPLAINED IN THIS ARTICLE.
Examples Of Non-Warrantable Grid Line Damage
^ Ice scraper damage to grid lines
^ Animal scratches on grid lines
^ Window tint film/removal of the film which damages grid lines
^ Stickers placed over grids which upon removal, removes the grid line material
^ License plate (steel type placed against the inside of back glass) which rubs on the grid line
causing damage
^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal
removes grid line material
^ Cargo or lumber rubbing against the glass which removes grid line material
^ Cellular phone antenna installation/removal which damages grid line material
NOTE
AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE
SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL
ACROSS THEM.
GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL
IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON
THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR
12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID
LINE INOPERATIVE - DIAGNOSTICS
1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power
and ground to the back-glass.
2. Connect a test lamp or DVOM to a good body ground.
3. Turn the ignition key to the run position and depress and release the rear defroster button to turn
the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME
THE DEFROSTER BUTTON IS PRESSED.
4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM +
lead to each grid line. (Use caution not to damage grid lines). The DVOM should read
approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test
light, the bulb should be approximately the same brightness on each line from top to bottom. If the
DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid
line with the + test lead or test lamp until the voltage changes suddenly. This is the area of
concern, use chalk to mark the area of concern and mark the outside of the glass at that same
area.
5. Repair per the Grid Line Repair Procedure.
GRID LINE REPAIR PROCEDURE
NOTE
LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE,
HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS
TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE
(5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING
DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER
THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND
EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT
VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID
LINE AREAS.
NOTE
IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY
RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT
FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND
SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW
DEFROSTER REPAIR COMPOUND.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11650
Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or
equivalent meeting Ford specification ESB-M4J58-A as follows:
Surface Preparation
1. Bring vehicle inside and warm it to 60° F (16° C) or above.
2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of
the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service
area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification
ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the
repair area be clean and dry.
NOTE
THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE
PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME.
Mixing
The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at
room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake
frequently during use.
Application
1. Mark location of open grid on the outside of the back window glass (performed in diagnostics).
Place protective covering over the package tray as necessary.
2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is
best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should
be at the center of the mask and tape gap must be no wider than the existing grid line. Other types
of tape may be used but end results of the repair may not appear as visually acceptable due to
ease of application and tape edge finish.
3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound
to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five
(5) minutes drying time between coats) across the open grid line area using the brush applicator in
the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area.
Apply a minimum of six (6) coats of the grid repair compound.
4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown
lacquer touch-up paint across the open line area first. Take care to paint only the area missing the
color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at
least five (5) minutes between coats. Apply six (6) coats of grid repair compound.
NOTE
THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER
TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE
REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11651
TIME TO MATCH THE REST OF THE GRID.
5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step
outside and inspect the repaired area. If the repair compound is visible above or below the grid, the
excess can be removed. This may be done by placing a single-edge razor blade on the back
window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better
but may not be cosmetically appealing.
CAUTION
BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID
LINES FUNCTION PROPERLY WHEN FINISHED.
Curing
The service coating will air-dry in approximately one (1) minute and the system can be energized
after five minutes. Maximum hardness and adhesion occur after approximately 24 hours.
SOLDER METHOD OF LEAD TERMINAL
NOTE
THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE.
PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY.
The new terminal will cover the original terminal location, but must be placed so that the new
terminal conductive areas will be placed on a good conductive base. This area should be cleaned
with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be
cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification
ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the
repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous
polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to
improve appearance.
CAUTION
DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS
PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE
EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY
AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER.
BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN
CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT
TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL.
The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a
visual indication when the terminal has reached the proper temperature to melt the solder on the
terminal. When the proper temperature is achieved the temperature paint will liquefy and change
color.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11652
Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus,
use type B (Figure 3).
NOTE
DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS
COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL.
SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL
ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR
MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE
ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE
BUSS-BAR ON GOOD CONDUCTIVE MATERIAL.
1. Place the replacement terminal over the original tab location making sure the conductive areas
of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original
location which does not have conductive material (figure 4).
2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the
terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle
may allow the terminal to slip when the solder liquefies).
3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab.
Energize the soldering gun and watch for the painted area of the terminal to liquefy and change
color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint
color completely changes on either side of the terminal, de-energize the soldering gun and
continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30)
seconds.
4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool
for another two (2) minutes before the wiring lead is attached to the terminal.
5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify
operation.
Parts Block
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Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11653
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042405A Repair Grid Lines (Includes 0.7 Hr.
Time To Diagnose And Recheck)
042405B Replace Terminal (Includes 0.4 Hr.
Time To Diagnose And Recheck)
042405C Repair Grid Lines And 0.8 Hr.
Replace Terminal (Includes Time To Diagnose And Recheck)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7042006 28
Disclaimer
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11658
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11659
Heated Glass Element Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11660
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Locations
Power Window Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions
Power Window Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11666
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11667
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11668
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11669
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11670
Circuit Identification Chart
System Codes Chart
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11671
Sample Diagrams
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11672
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11673
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11674
Circuit Identification Chart
SYSTEM CODES CHART
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11675
SAMPLE DIAGRAMS
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11676
Sample Diagram
Sample Diagram
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11677
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11678
Symbols
Symbols
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11679
Symbols
Symbols
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11680
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11681
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11682
Power Window Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11685
Power Window Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
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Power Window Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
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Module > Component Information > Diagrams > Page 11687
Power Window Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations
Diagram 700-01-00-6
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Component Information > Diagrams > Window Safety Relay
Power Window Relay: Diagrams Window Safety Relay
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Component Information > Diagrams > Window Safety Relay > Page 11693
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Component Information > Testing and Inspection > Window Safety Relay
Power Window Relay: Testing and Inspection Window Safety Relay
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Component Information > Testing and Inspection > Window Safety Relay > Page 11696
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
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Component Information > Testing and Inspection > Window Safety Relay > Page 11697
Power Window Relay: Testing and Inspection One-Touch Window Relay
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Component Information > Testing and Inspection > Window Safety Relay > Page 11698
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
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Switch > Component Information > Diagrams
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Component Information > Diagrams > Rear Window Adjust Switch
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Component Information > Diagrams > Rear Window Adjust Switch > Page 11707
Power Window Switch: Diagrams Master Window Adjust Switch
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Component Information > Diagrams > Rear Window Adjust Switch > Page 11708
Power Window Switch: Diagrams Window Adjust Switch
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Component Information > Diagrams > Rear Window Adjust Switch > Page 11709
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Component Information > Testing and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Power Window Switch: Testing and Inspection Power window Switch
Passenger Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11714
Left Rear Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11715
Right Rear Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11716
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Power Window Switch: Service and Repair
REMOVAL
NOTE: Driver window control switch shown, all others are similar.
Front door
1. Disconnect the battery ground cable.
All doors
2. Remove the window control switch panel.
^ Disconnect the electrical connectors.
3. Remove the window control switch.
^ Release the locking clips.
INSTALLATION
1. To install, reverse the removal procedure.
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Locations
Power Window Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
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Diagrams > Diagram Information and Instructions
Power Window Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
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Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
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Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
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Circuit Identification Chart
System Codes Chart
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Sample Diagrams
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Sample Diagram
Sample Diagram
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Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
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Circuit Identification Chart
SYSTEM CODES CHART
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SAMPLE DIAGRAMS
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Sample Diagram
Sample Diagram
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Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
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Symbols
Symbols
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Symbols
Symbols
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Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
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Power Window Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Power Window Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
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Power Window Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
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Power Window Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Diagrams > Left Front
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Component Information > Diagrams > Left Front > Page 11751
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Diagrams > Page 11752
Front Door Window Motor: Service Precautions
CAUTION: Use care not to damage the drum housing when removing the rear window glass motor.
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Component Information > Diagrams > Page 11753
Front Door Window Motor: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Remove the front door speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
3. Remove the water shield.
4. Disconnect the front door window regulator motor electrical connector.
5. Drill a 13 mm (0.52 in) hole using the locator in the door sheet metal as a guide.
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6. Remove the bolts and the front door window regulator motor.
INSTALLATION
1. To install, reverse the removal procedure.
^ Cycle the door glass to make sure of engagement of the drive mechanism.
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Component Information > Diagrams > Left
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Component Information > Diagrams > Left > Page 11759
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Diagrams > Left > Page 11760
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Diagrams > Page 11761
Rear Door Window Motor: Service Precautions
CAUTION: Use care not to damage the drum housing when removing the rear window glass motor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair > Rear Door Window Regulator Motor
Rear Door Window Motor: Service and Repair Rear Door Window Regulator Motor
REMOVAL
1. Remove the rear door window regulator.
2. Remove the rear door window regulator motor.
1 Remove the bolts.
2 Remove the rear door window regulator motor.
INSTALLATION
1. To install, reverse the removal procedure.
^ Cycle the door glass to make sure of engagement of the drive mechanism.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 11764
Rear Door Window Motor: Service and Repair Rear Window Glass Motor
REMOVAL
1. Remove the C-pillar trim panel. 2. Position the rear of the carpet aside. 3. Remove the water
shield from over the rear window glass motor and discard.
4. Remove the rear window motor.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the rear window glass motor.
CAUTION: Use care not to damage the drum housing when removing the rear window glass motor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The rear window motor must be initialized after a repair is carried out.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 11765
Rear Door Window Motor: Service and Repair Rear Window Motor Initialization
1. Start with the ignition key in the OFF position. 2. Turn the ignition key to the ON position. 3.
Press the rear window glass control switch vent button six times. 4. Turn the ignition key to the
OFF position. 5. Press the rear window glass control switch vent button six more times. 6. Turn the
ignition key to the ON position. At this point the rear window glass will move up and down
approximately 20 mm (0.8 in). This
movement signifies that the rear window glass motor has entered into the initialization mode.
7. Hold the rear window glass control switch in the full up position until the rear window glass stops
in the full up position.
NOTE: The rear window glass control switch must be held in the up or down position until the
window glass stops moving. Failure to hold the switch will end the initialization operation. Then
initialization will have to be re-started.
8. Hold the rear window glass control switch in the full down position until the rear window glass
stops in the full down position.
NOTE: If a repair is to be carried out on the rear window glass release the rear window glass
control switch when it reaches the desired position. This will end the initialization operation.
9. Hold the rear window glass control switch in the full, up position until the rear window glass stops
in the full up position. At this time the window
will move up and down approximately 20 mm (0.8 in) signifying the rear window glass motor is
initialized.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations
Diagram 700-01-00-6
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams >
Window Safety Relay
Power Window Relay: Diagrams Window Safety Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams >
Window Safety Relay > Page 11771
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Inspection > Window Safety Relay
Power Window Relay: Testing and Inspection Window Safety Relay
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Inspection > Window Safety Relay > Page 11774
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground.
Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not,
replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86.
If the voltage is 12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Inspection > Window Safety Relay > Page 11775
Power Window Relay: Testing and Inspection One-Touch Window Relay
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Inspection > Window Safety Relay > Page 11776
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Rear Window Adjust Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Rear Window Adjust Switch > Page 11781
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Rear Window Adjust Switch > Page 11782
Power Window Switch: Diagrams Window Adjust Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Rear Window Adjust Switch > Page 11783
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11786
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11787
Power Window Switch: Testing and Inspection Power window Switch
Passenger Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11788
Left Rear Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11789
Right Rear Door
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11790
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 11791
Power Window Switch: Service and Repair
REMOVAL
NOTE: Driver window control switch shown, all others are similar.
Front door
1. Disconnect the battery ground cable.
All doors
2. Remove the window control switch panel.
^ Disconnect the electrical connectors.
3. Remove the window control switch.
^ Release the locking clips.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service
Precautions
Window Frame: Service Precautions
CAUTION: Use care not to damage the pin-type retainers retaining the upper corner of the door
glass top run.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and
Repair > Front Door
Window Frame: Service and Repair Front Door
REMOVAL
1. Remove the front door trim panel.
2. Remove the interior glass weather strip.
3. Release the two pin-type retainers.
CAUTION: Use care not to damage the pin-type retainers retaining the upper corner of the door
glass top run.
4. Remove the front door glass top run bolts. 5. Remove the front door glass top run.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and
Repair > Front Door > Page 11797
Window Frame: Service and Repair Rear Door
REMOVAL
1. Remove the rear door window glass.
2. Remove the rear door glass top run bolt.
3. Remove the door glass top run.
CAUTION: Use care not to damage the pin-type retainers retaining the upper forward comer of the
door glass top run.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Fixed
Back Window Glass: Service and Repair Fixed
REMOVAL
1. Remove the C-pillar trim panel.
2. Remove the 15 rear window glass nuts and remove the rear window glass. 3. Remove the
excess foam butyl from the window opening.
INSTALLATION
1. To install, reverse the removal procedure.
^ Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the
rear window glass.
^ Start at the bottom middle and work around the window opening.
NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Fixed > Page 11803
Back Window Glass: Service and Repair Power
REMOVAL
1. Remove the C-pillar trim panel. 2. Position the rear of the carpet aside.
3. Position the rear window glass regulator access panel aside.
1 Remove the screws.
2 Remove the nut.
3 Position the rear window glass regulator access panel aside.
4. Remove the rear window weatherstrip moulding. 5. Position the rear window glass to the center
position using the following procedure.
1 Start with the ignition key in the OFF position.
2 Turn the ignition to the ON position.
3 Press the rear window glass control switch vent button six times.
4 Turn the ignition key to the OFF position.
5 Press the rear window glass control switch vent button six more times.
6 Turn the ignition to the ON position. At this point the rear window will move up and down
approximately 20 mm (0.8 in). This movement signifies that the rear window glass motor has
entered into the initialization mode.
7 Hold the rear window glass control switch in the full up position until the rear window glass stops
in the full up position.
8 Hold the rear window glass control switch in the full down position until the rear window glass
stops in the full down position.
9 Hold the rear window glass control switch in the full up position until the rear window glass in the
center position and release the switch.
10 Turn the key to the OFF position.
6. Remove the rear window glass bolts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Fixed > Page 11804
7. Secure the rear window glass in the full up position.
NOTE: When securing the rear window glass note that the rear window glass and module will be
removed with the rear window glass in the secured position.
8. Remove the 12 rear window glass module nuts. 9. Push the rear window glass module out at the
top.
10. Lift the rear window glass module from the rear of the cab to disengage the locating clip.
NOTE: In order for the rear widow glass to function correctly the locating clip must engage the
pinch weld at the rear of the cab during installation.
11. Remove the excess foam butyl from the window opening.
12. If necessary, remove the center rear window glass from the module.
INSTALLATION
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Fixed > Page 11805
1. To install, reverse the removal procedure.
^ Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the
rear window glass module.
^ Start at the bottom and work around the module.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair
Front Door Window Glass: Service and Repair
Heavy Duty Riverter
SPECIAL TOOL(S)
REMOVAL
1. Remove the front door trim panel.
2. Remove the front door belt line moulding.
1 Remove the nut.
2 Remove the moulding.
CAUTION: Do not strike or force the front door belt line moulding during installation. The front door
belt line moulding is made of aluminum and will be damaged.
NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge
of the sheet metal and the door panel shelf.
3. Remove the interior glass weatherstrip.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair > Page 11809
4. Remove the front door window glass rivets.
NOTE: Lower the window glass to access the rivets.
5. Remove the front door window glass through the outboard side of the front door.
INSTALLATION
1. To install, reverse the removal procedure.
^ Use the special tool to install the rivets.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair
Liftgate Window Glass: Service and Repair
REMOVAL
1. Open the liftgate glass.
2. Remove the two heated rear window electrical connector covers.
3. Disconnect the two heated rear window electrical connectors.
4. Remove the two liftgate lifting cylinder pins.
NOTE: An assistant may be needed to carry out this step.
5. Remove the liftgate window glass.
1 Position the liftgate trim panel aside.
2 Remove the access the covers and the liftgate window hinge nuts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair > Page 11813
NOTE: An assistant may be needed to carry out this step.
6. Remove the liftgate window glass.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Fixed
Quarter Window Glass: Service and Repair Fixed
REMOVAL
1. Remove the quarter trim panel.
2. Remove the rear quarter window glass.
1 Remove the nuts.
2 Push the rear quarter window glass outward to release the butyl seal.
3. Remove the excess foam butyl from the window opening.
INSTALLATION
1. Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to
the rear quarter window glass frame.
^ Start at the bottom middle and work around the frame.
NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage.
2. Install the rear quarter window glass.
1 Position the rear quarter window glass.
2 Tighten the nuts.
NOTE: Loosely install the nuts before tightening.
3. Install the quarter trim panel.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Fixed > Page 11818
Quarter Window Glass: Service and Repair Movable Quarter
REMOVAL
1. Remove the quarter trim panel.
2. Remove the quarter window glass.
1 Remove the nuts.
2 Remove the quarter window glass.
INSTALLATION
1. To install, reverse the removal procedure.
^ If the seal requires adjustment, disconnect the quarter window latch from the quarter trim panel.
Rotate the quarter window latch clockwise to increase seal pressure or counterclockwise to reduce
seal pressure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair
Rear Door Window Glass: Service and Repair
Heavy Duty Riverter
SPECIAL TOOL(S)
REMOVAL
1. Remove the rear door trim panel.
2. Remove the interior glass weatherstrip.
3. Remove the rear door belt line moulding nut.
4. Remove the rear door belt line moulding.
CAUTION: Do not strike or force the front door belt line moulding during the installation. The front
door belt line moulding is made of aluminum and will be damaged.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Page 11822
NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge
of the sheet metal and the door panel shelf.
5. Remove the rear door window glass rivets.
6. Remove the rear door window glass through the outboard side of the rear door.
INSTALLATION
1. To install, reverse the removal procedure.
^ Use the special tool to install the rivets.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair
Front Door Window Regulator: Service and Repair
Heavy Duty Riverter
SPECIAL TOOL(S)
REMOVAL
1. Raise the front door window glass to the full up position. 2. Remove the interior door handle. 3.
Support the front door window glass.
4. Disconnect the front door window regulator motor electrical connector.
5. Remove the equalizer bracket nuts.
6. Remove the front door window regulator.
1 Remove the rivets.
2 Remove the nut.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 11827
7. Remove the front door window regulator motor.
1 Remove the bolts.
2 Remove the front door window regulator motor.
INSTALLATION
1. To install, reverse the removal procedure.
^ Use the special tool to install the rivets.
^ Cycle the door glass to make sure of engagement of the drive mechanism.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 11828
Heavy Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair
Rear Door Window Regulator: Service and Repair
Heavy Duty Riverter
SPECIAL TOOL(S)
REMOVAL
1. Raise and support the rear door window glass to the full up position. 2. Remove the interior door
handle.
3. Remove the rear door speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
4. Remove the water shield.
5. Disconnect the rear door window regulator motor electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair > Page 11832
6. Remove the rear door window regulator rivets.
7. Remove the rear door window regulator.
^ Slide the regulator arms off of the window glass track.
INSTALLATION
1. To install, reverse the removal procedure.
^ Use the special tool to install the rivets.
^ Cycle the door glass to make sure of engagement of the drive mechanism.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair > Page 11833
Heavy Duty Riveter
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician
Safety Information
Windshield: Technician Safety Information
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING
HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM
THE VEHICLE.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician
Safety Information > Page 11838
Windshield: Vehicle Damage Warnings
CAUTION:
^ After installing the urethane installed glass, the vehicle should not be driven until the urethane
adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity
above 50% is 12-24 hours (refer to Essex Drive Away Chart for cure times, as temperatures and
humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the
urethane bond.
^ Do not scratch the pinch weld area.
^ If the vehicle is to be driven within 24 hours of urethane application, urethane adhesive Essex
U-216 must be used due to its one hour cure time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
11839
Windshield: Service and Repair
SPECIAL TOOL(S)
REMOVAL
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING
HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM
THE VEHICLE.
1. Remove the windshield side garnish mouldings. 2. Remove the interior rear view mirror. 3.
Remove the overhead console.
4. Remove the sun visors.
1 Remove the sun visor screws.
2 Remove the sun visors.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
11840
^ if equipped, disconnect the electrical connector.
5. Remove the sun visor clips.
1 Remove the sun visor clip screws.
2 Remove the sun visor clips.
6. Lower the front portion of the headliner. 7. Remove the cowl grille.
8. Remove the upper windshield weatherstrip.
9. Remove the LH and RH windshield mouldings.
10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
11. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top
center and work toward the bottom corners.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
11841
NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting.
12. Using the special tool, distance the windshield from the body.
13. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
14. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld.
INSTALLATION
CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the
urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative
humidity above 50% is 12-24 hours (refer to Essex Drive Away Chart for cure times, as
temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect
the strength of the urethane bond.
1. Dry fit the windshield. Make alignment marks with tape or non-staining grease pencil.
2. Trim the remaining urethane adhesive on the pinch weld to within the specification.
^ The existing urethane adhesive surface should be smooth and free of cuts and contamination.
CAUTION: Do not scratch the pinch weld area.
3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification
WSB-M2G234-C to any exposed metal on the
pinch weld. Allow six to ten minutes to dry.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
11842
4. Apply (A) Foam Dam meeting Ford specification WSB-M2G234-C to the (B) pinch weld. 5. If
reinstalling original windshield, remove the excess urethane adhesive from the windshield glass. 6.
Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic coated
area is clean. 7. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401
meeting Ford specification WSB-M2G314-B twice around the glass
surface to be urethaned.
NOTE: Wipe off the Glass Prep immediately after each application because it flash dries.
8. If installing a new windshield glass, apply Glass Primer Essex U-402 meeting Ford specification
WSB-M5B280-C to the same area that was
prepped in the pervious step. Allow five minutes to dry.
9. Cut the urethane adhesive applicator tip to specification.
10. Apply a bead of urethane adhesive Essex 400-HV or Essex U-216, which meets Ford
specification WSB-M2G316-B to the pinch weld just outside
the foam dam.
CAUTION: If the vehicle is to be driven within 24 hours of urethane application, urethane adhesive
Essex U-216 must be used due to its one hour cure time.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
11843
11. Install the windshield glass aligning it to the marks previously made. 12. After the windshield
glass is set, check for water leaks and add urethane adhesive where needed.
13. Install the upper windshield weatherstrip. 14. If necessary, remove excess urethane adhesive
from the outside surface of the windshield glass.
15. Install the LH and RH windshield mouldings. 16. Install the cowl grille. 17. Install the overhead
console.
18. Install the sun visor clips.
1 Position the sun visor clips.
2 Install the screws.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
11844
19. Install the sun visors.
1 Position the sun visors. ^
If equipped, connect the electrical connector.
2 Install the screws.
20. Install the front portion of the headliner. 21. Install the interior rear view mirror.
22. Install the windshield side garnish mouldings.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
11845
Special Tool(s)
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Locations
Windshield Washer Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11853
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11854
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11855
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11856
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11857
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11858
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11859
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11860
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11861
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11862
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11863
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11864
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11865
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11866
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11867
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11868
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11869
Windshield Washer Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11870
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11871
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11872
Windshield Washer Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11873
Windshield Washer Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Page 11874
Windshield Washer Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Diagrams > Windshield Washer Relay, Front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Diagrams > Windshield Washer Relay, Front > Page 11880
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Diagrams > Page 11881
Windshield Washer Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Diagrams > Page 11882
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations
Wiper Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Wiper Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11888
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11889
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11890
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11891
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11892
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11893
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11894
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11895
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11896
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11897
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11898
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11899
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11900
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11901
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11902
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11903
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11904
Wiper Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11905
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11906
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11907
Wiper Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11908
Wiper Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Page 11909
Wiper Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Wiper High/Low Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Wiper High/Low Relay > Page 11915
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Wiper High/Low Relay > Page 11916
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Wiper High/Low Relay > Page 11917
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Page 11918
Wiper Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Page 11919
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 11924
Windshield Washer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 11925
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 11930
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 11931
Wiper Switch: Diagrams Multi-Function Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 11932
Wiper Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 11933
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 11934
Wiper Switch: Service and Repair
REMOVAL
1. Remove the instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
2. Remove the rear wiper/washer switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the rear wiper/washer switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Locations
Windshield Washer Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions
Windshield Washer Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11940
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11941
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11942
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11943
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11944
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11945
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11946
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11947
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11948
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11949
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11950
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11951
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11952
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11953
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11954
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11955
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11956
Windshield Washer Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11957
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11958
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11959
Windshield Washer Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 11960
Windshield Washer Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Page 11961
Windshield Washer Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
Precautions
Windshield Washer Pump: Service Precautions
WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS
POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF
THE WASHER SOLUTION CONTAINER.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
Precautions > Page 11968
Windshield Washer Pump: Service and Repair
REMOVAL
1. Remove the engine air cleaner; refer to Fuel Delivery and Air Induction.
2. Remove the windshield wiper reservoir fasteners.
1 Remove the two screws.
2 Remove the two nuts.
3. Disconnect the windshield washer reservoir pump electrical connector. 4. Disconnect the
windshield washer hose from the windshield washer pump and plug the outlet of the pump.
WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS
POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF
THE WASHER SOLUTION CONTAINER.
5. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the
outlet of the reservoir.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
Precautions > Page 11969
6. Remove the windshield washer pump.
NOTE: Make sure not to damage the rubber grommet during disassembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams >
Windshield Washer Relay, Front
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams >
Windshield Washer Relay, Front > Page 11975
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams >
Page 11976
Windshield Washer Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams >
Page 11977
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Page 11981
Windshield Washer Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Page 11982
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments
Wiper Arm: Adjustments
1. Cycle and park the windshield wipers.
2. Verify the distance between the center of the passenger windshield wiper blade and the rear
edge of the cowl top vent panel is within
specifications.
3. Verify the distance between the center of the driver windshield wiper blade and the rear edge of
the cowl top vent panel is within specifications. 4. If the distance is not within specifications, remove
the windshield wiper pivot arms and reposition to specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot
Arm-Front
Wiper Arm: Service and Repair Pivot Arm-Front
REMOVAL
1. Remove the wiper pivot arm.
1 Pull up on the wiper pivot arm.
2 Pull out on the retainer tab and lower the wiper pivot arm to the tab.
3 Remove the wiper pivot arm.
NOTE: The wiper pivot arms are installed as an assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot
Arm-Front > Page 11988
Wiper Arm: Service and Repair Pivot Arm-Rear
REMOVAL
1. Disconnect the rear washer hose.
2. Remove rear wiper pivot arm.
1 Lift the wiper pivot arm nut cover at the point shown.
2 Remove the nut.
3 Remove the wiper pivot arm.
NOTE: The wiper pivot arm must be lifted straight up from the shaft to avoid damage to the wiper
pivot arm or shaft.
INSTALLATION
1. Turn the rear wiper switch on and allow the motor to operate for at least one cycle.
2. Turn the rear wiper switch OFF.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot
Arm-Front > Page 11989
NOTE: This step makes sure that the wiper motor is in the park position.
3. Position the rear wiper blade outside the wiper arm stop.
4. Install the wiper pivot arm onto the wiper motor.
^ Tighten retaining nut.
5. Connect the washer hose to the elbow with elbow positioned between the 9:00 and 12:00 o'clock
positions.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments
Wiper Blade: Adjustments
1. Cycle and park the windshield wipers.
2. Verify the distance between the center of the passenger windshield wiper blade and the rear
edge of the cowl top vent panel is within
specifications.
3. Verify the distance between the center of the driver windshield wiper blade and the rear edge of
the cowl top vent panel is within specifications. 4. If the distance is not within specifications, remove
the windshield wiper pivot arms and reposition to specification.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
Wiper Control Module: Locations
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Locations.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions
Wiper Control Module: Diagram Information and Instructions
Early Production/Late Production Defined
NOTE: The build date can be found on the Vehicle Certification (VC) label.
Early Production
Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module.
Late Production
Built AFTER 7/24/2000. Uses the Central Security Module.
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Note: All wiring connections between components are shown exactly as they exist in the vehicles. It
is important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation Each circuit is shown completely and independently in one set of
diagrams. Other components which are connected to the circuit may not be shown unless they
influence the circuit operation.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 11998
Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit
such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the
diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts,
power supply and ground connections are sometimes simplified by a dashed line in the diagrams.
Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if
the Ignition Switch were OFF).
Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown
completely in the diagram but is complete within the set of diagrams, the number of the diagram
where the splice is completed is indicated next to the arrow.
Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a
particular vehicle model, country, or option. These qualifiers are shown next to the box on the
diagram.
Component Names and Notes (5) Component names are placed on the right hand side of each
component. Any notes that describe switch positions or operating conditions follow the name.
Descriptions of the internals of the component are also included here.
Component Identification Numbers (6) Each component on each diagram has a component
identification number located to the upper right hand side of the component. By finding this number
in the A-Z Component List, the Component Location description for that component can easily be
found.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 11999
Fuse And Relay Information
Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the
fuse/relay box in which all fuses and relays are identified.
Power Distribution
Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown
from the battery to the ignition switch and to all fuses.
Fuse Circuits
Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The
circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the
fuse and the first component are shown.
Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery.
Ground Distribution
Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual sets of diagrams as uncluttered as possible.
Splices with a large number of wires may be split in order to improve the graphic representation. A
thin line is used to indicate the unity of the splice. The splice is then marked with the additional text
"partial".
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12000
Component Identification Information Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. The
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number.
Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or
pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the
way out by a spring.
Some vacuum motors can position the actuating arm at any position between fully extended and
fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to
the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors
work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo
Motors are generally larger and provide a calibrated control.
A double diaphragm motor has three positions (it is actually two motors in one housing). When the
top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the
way in.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tall pipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
circuit Numbering
Circuit Numbering and Wire Identification
Circuit Numbering:
Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The
system is called Function, System-Connection, or FSC for short. FSC was developed mainly to
assist in vehicle development and production processes, but is also helpful in troubleshooting
electrical circuits. Function:
The first two digits identify the function of the wire. In this case, the function code includes the letter
"S" to indicate it is an additionally switched function. The function part of the circuit number is the
most helpful to the technician in troubleshooting a circuit.
System-Connection (including branch):
Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code
is the connection number specific to that system. A branch identification is used to differentiate
wires in one connection with the same function.
Wire Identification (wire colors):
The wire identification consists of a basic color and an identification color, and is determined
directly from the wire's circuit number. In the schematics the wire colors are indicated next to the
wires. The basic and identification colors are abbreviated using the international norm IEC 757.
Each function code has a specific basic color associated with it. A colored stripe is used to
differentiate several wires with the same function within one component connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12001
Wire Identification Example
Using the circuit number and wire identification used in the Wire Identification Example, we know
the following information about the wire:
Function: 31 = Ground S = Additionally switched circuit
System: AC = Headlamp leveling
Connection: 3 = Switch connection
A = Branch
Size: 1.5 = 1.5 sq.mm
Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe).
Circuit Identification Charts
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12002
Circuit Identification Chart
System Codes Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12003
Sample Diagrams
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12004
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12005
Sample Diagram
Circuit Identification Charts and System Codes
CIRCUIT IDENTIFICATION CHARTS
Circuit Identification Chart
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12006
Circuit Identification Chart
SYSTEM CODES CHART
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12007
SAMPLE DIAGRAMS
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12008
Sample Diagram
Sample Diagram
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12009
Sample Diagram
Electrical Symbols
ELECTRICAL SYMBOLS
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12010
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12011
Symbols
Symbols
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12012
Types of Diagrams Shown
Types of Diagrams Shown
Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams
provide an overview of the systems that are detailed on the detailed diagrams that follow them.
Block diagrams are not suitable for diagnostic operations.
Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system
information suitable for diagnostic operations.
Related Diagrams that are not an intergal part of the detailed diagrams, but may have a
relationship to them, are also included.
All components connected to the control module are shown in order to provide easy understanding
of the system component interactions.
Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type.
Wire Color Code Identification
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12013
Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural
OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12014
Wiper Control Module: Diagnostic Aids
These illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12015
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12016
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12017
Wiper Control Module: Connector Views
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12018
Wiper Control Module: Electrical Diagrams
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module); Diagrams.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Page 12019
Wiper Control Module: Application and ID
For further information regarding this component please refer to Multifunction Electronic Control
Modules (General Module).
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications
Torque Specifications
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield
Wiper Motor
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield
Wiper Motor > Page 12025
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 12026
Wiper Motor: Service Precautions
CAUTION:
^ The internal permanent magnets used in the windshield wiper motor are made of a glass-like
material. To avoid damaging the magnets, do not strike the motor with a hammer or any other
object.
^ Read the installation label on the rear wiper motor before installing in vehicle to prevent
component damage. Do not activate rear wiper motor until windshield wiper arm and blade are
correctly installed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 12027
Wiper Motor: Testing and Inspection
Use Alternator, Regulator, battery and Starter Tester (ARBST) to test the wiper motor on the
vehicle.
To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the
windshield wiper motor.
Disconnect the wiper motor. Connect the (1) green lead from (2) Alternator, Regulator, Battery and
Starter Tester (ARBST) to the battery negative (-) post. Connect the (3) red lead from ARBST to
the wiper motor (4) common brush terminal (terminal 3).
Test the low speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low
speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than
3.5 amperes, install a new windshield wiper motor.
Test the high speed mode by connecting a cable from the battery positive (+) post to the (7) high
speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than
5.5 amperes, install a new wiper motor.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor
Wiper Motor: Service and Repair Windshield Wiper Motor
REMOVAL
1. Disconnect the washer hose from the LH washer jet nozzle. 2. Remove the cowl grilles.
3. Unsnap the wiper motor clip from the RH wiper mounting arm and pivot shaft.
4. Disconnect the RH wiper mounting arm and pivot shaft from the LH wiper mounting arm and
pivot shaft and move both away from the windshield
wiper motor.
5. Disconnect the electrical connector.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 12030
6. Remove the ground strap nut and position the strap aside.
7. Remove the windshield wiper motor.
^ Remove the stud bolts.
^ Remove the bolts.
CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a
glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any
other object.
INSTALLATION
1. Install the windshield wiper motor.
1 Install the windshield wiper motor.
2 Install the stud bolts.
3 Install the bolts.
CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a
glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any
other object.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 12031
2. Install the ground strap and nut.
3. Connect the electrical connector.
4. Install the wiper mounting arm and pivot shaft arms to the windshield wiper motor.
1 Install the LH wiper mounting arm and pivot shaft onto the windshield wiper motor crank pin.
2 Install the RH wiper mounting arm and pivot shaft onto the wiper motor crank pin.
3 Push the retaining clip until it snaps into place.
5. Install the cowl grilles.
6. Connect the washer hose to the LH washer jet nozzle. 7. Install the LH wiper pivot arm. 8. Adjust
the LH wiper pivot arm.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 12032
Wiper Motor: Service and Repair Rear Window Wiper Motor
REMOVAL
1. Remove the rear wiper pivot arm. 2. Remove the liftgate door trim panel. 3. Remove the
watershield.
4. Remove rear wiper motor.
1 Disconnect electrical connector.
2 Remove three retaining bolts.
3 Remove rear wiper motor.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Read the installation label on the rear wiper motor before installing in vehicle to prevent
component damage. Do not activate rear wiper motor until windshield wiper arm and blade are
correctly installed.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service
Precautions
Wiper Motor Linkage: Service Precautions
CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be
sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield
wiper motor crank pin.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service
Precautions > Page 12036
Wiper Motor Linkage: Service and Repair
REMOVAL
1. Remove the cowl grilles.
2. Unsnap the wiper motor clip from the RH wiper mounting arm and pivot shaft.
3. Disconnect the RH wiper mounting arm and pivot shaft from the LH wiper mounting arm and
pivot shaft and move both away from the windshield
wiper motor.
4. Remove the RH and LH wiper mounting arm and pivot shafts.
1 Remove the two nuts.
2 Remove the wiper mounting arm and pivot shafts.
INSTALLATION
1. Install the RH and LH wiper mounting arms and pivot shafts.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service
Precautions > Page 12037
1 Position the wiper mounting arm and pivot shafts into place.
2 Install the two nuts.
2. If removed, install the clip onto the RH wiper mounting arm and pivot shaft.
CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be
sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield
wiper motor crank pin.
3. Install the wiper mounting arm and pivot shaft assemblies.
1 Install the LH wiper mounting arm and pivot shaft onto the windshield wiper motor crank pin.
2 Install the RH wiper mounting arm and pivot shaft onto the wiper motor crank pin.
3 Push the retaining clip until it snaps into place.
4. Install the cowl grilles. 5. Adjust the LH and RH wiper pivot arms.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Diagram 700-01-00-1
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper
High/Low Relay
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper
High/Low Relay > Page 12043
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper
High/Low Relay > Page 12044
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper
High/Low Relay > Page 12045
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 12046
Wiper Relay: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 12047
COMPONENT TESTING PROCEDURE (Voltage Applied)
Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure
voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the
relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is
12V, the relay is okay. If not, replace the relay.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear
Window Wiper Disable Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear
Window Wiper Disable Switch > Page 12052
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear
Window Wiper Disable Switch > Page 12053
Wiper Switch: Diagrams Multi-Function Switch
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page
12054
Wiper Switch: Testing and Inspection
Component Testing Instructions
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic with component terminal locations
and step-by-step test procedures. Component terminals are identified by letters or numbers that
may be marked on the component or callout if there is no mark on the component.
The component connector MUST BE REMOVED before testing. To test a single circuit within the
component, select that circuit under the column TO TEST. If you wish to test the complete
component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as
shown in the third column.
Ford Explorer Sport 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page
12055